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1. 4 9 Smart Line Modules 4 9 4 SLM 16 kW and higher connections Connections x21 Terminal P f SE ZY X200 X202 X24 24 V terminal adapter Unlocking Protective cover Electronics power P a supply Va 0 5 x 3 5 DC link busbars Protective cover LEDs Protective conductor Line connection connection M5 3 Nm Shield plate Figure 4 23 Connections SLM 2 16 kW Hardware and Software 124 Service Manual 03 2010 6FC5397 5DP20 0BA0 Service cases hardware 4 9 5 Overview Removing Hardware and Software 4 9 Smart Line Modules This is how you remove an SLM The activities that must be taken into account when replacing a Smart Line Module SLM are subsequently described If a module has a hardware defect then it must be replaced by an identical module Preconditions e The module is defective and must be replaced e The control cabinet is in a no voltage condition all of the connectors and cables are labeled NOTICE Electro static discharge ESD Before you touch the module discharge yourself at the cabinet or at the ground terminal Procedure 1 Switch off the control Completely switch off the system Check that the system is in a no voltage condition and is locked out so that it cannot be switched on again without the appropriate authorization 2 Access the control cabinet where the infeed module is located 3 If it has not alr
2. ec eeececeeeeeeeeeeeeeteeeeaeeeeeeaaeeeeeeaaeeeeeeaeeeeeeaeeeeneaas 32 3 3 2 This is how you install a software DACKUD ccceeeeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeaaeeeeeeaaeeeeeeaeeessenaeeeenaaes 36 3 4 Software update ccecececceccececeeeeeceeeae cece cece eeceaeaeceeeeeeesecaaeaeeeeeeeeeeceaeaeeeeesesecsnaeeeeeeseeeeesenneneess 40 3 4 1 This is how you update the sofware eee eceeeeeeeeeeeeeeeeeeaeeeseeaaeeeeeeaaeeeseeaaeeeeeeaaeeeseenaeeeeeaaas 40 3 5 Mini boot system on the CompactFlash Card s sesssssesessrrssssnnearsnnenrnnnaneenndenannaattnneatannaaetnnadnaana 44 3 5 1 This is how you generate a mini boot SYStOM ee ce ceeeeeeeeneeeeeeeaeeeeeeaaeeeeeeaaeeeeeeaeeeeeenaeeeeeeaas 44 3 5 2 This is how you install a software backup using the mini boot SysteM ec eeeeeeeeeeteeeeeeeee 48 3 6 LICENSING E E A E E asec cevauedecbasandcueruaddccuatantectebncesebaactecertae 51 3 6 1 Licensing after replacing the system CompactFlash Card ssseseeseeseessesireseerreserrrssrrrrssrerrssreens 51 3 6 2 This is how you license a CNC Option oo ecccccceeceeee nanan enaa A aa a aa AA S 51 3 6 3 How to determine the license requirement ceeeeeeeccee cece ee eeeeeeecaeceeeeeeeeenacaeeeeeeeeetecsiaeenees 53 3 6 4 This is how you generated a new license Key ee cceceeeeeeeeeeeeeeeceeeeeeeeeaaeeeeeeaeeeeeeaeeeesenaeeeeeeaas 54 3 6 5 This is how you display the actual license Key essscsesse
3. 5 Confirm the confirmation prompt by pressing the lt INPUT gt key Are you sure you want to reload saved user data Note Booting If data is lost from the buffer memory the data saved in the permanent memory will automatically be reloaded to the memory at POWER ON If the control boots with the backed up data the following message is displayed 4062 Data backup copy has been loaded Hardware and Software 22 Service Manual 03 2010 6 C5397 5DP20 0BAO Service cases software 3 2 Overview 3 2 1 3 2 Series commissioning Series commissioning A series commissioning archive is used to completely backup all of the data required for the machine function A series commissioning archive can be generated on an external data carrier e g USB FlashDrive or CompactFlash Card at the front panel of the control as well as on the system CompactFlash Card Note Data must always be backed up before a machine is delivered Only then can it be ensured that in the case of service the delivery condition of the machine can be restored In addition it may be necessary to generate a series commissioning archive before service activities are started This means that it can be guaranteed that the actual state of the machine can be restored after the activities have been completed This is how you generate a series commissioning archive on an external data carrier Generating an archive on an external data
4. Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 75 Service cases hardware 4 2 Replacing the system CompactFlash Card 4 2 Replacing the system CompactFlash Card 4 2 1 This is how you remove the system CompactFlash Card Overview If service is required it may be necessary to replace the system CompactFlash Card of the control This is the case if e g the system CompactFlash Card or the PPU is defective CAUTION Electro static discharge ESD The system CompactFlash card must only be inserted or removed in a no current condition Before you touch the CompactFlash Card discharge yourself at the cabinet or at the ground terminal Removing the system CompactFlash Card Procedure 1 Switch off the power supply of the control and the control cabinet 2 Release the screw M3 Hardware and Software 76 Service Manual 03 2010 6FC5397 5DP20 0BAO Service cases hardware 4 2 Replacing the system CompactFlash Card 3 Move the metal cover to the side and remove it Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BAO 77 Service cases hardware 4 2 Replacing the system CompactFlash Card 6 Fix the metal cover to the housing using the screw When removing the system CompactFlash Card carefully ensure that neither the screw nor the system CompactFlash Card falls into the PPU or the machine PPU as replacement part Note For a PPU as re
5. SFCSOOO ONPET OYDB O z CSO ENTS OYE i Series a Li far Prog El start u 2 censes 1 list Figure 3 4 Licensing example 4 To activate new selected options press the Reset po softkey A safety prompt appears 5 Press the OK softkey to trigger a warm restart OR 6 Press the Cancel softkey to cancel the process This is how you generated a new license key Assigning the license to hardware 54 In order to simplify licensing for the technician licenses are assigned to the hardware in a Standard Web Browser using the Web License Manager To conclude the assignment the license key must be entered manually on the control via the user interface As a consequence a valid license key can be generated at any time worldwide for options that have been additionally purchased Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO Service cases software 3 6 Licensing Preconditions The following preconditions must be met in order to assign a license to a piece of hardware via direct access and user interface e Hardware serial number e A PC PG with Internet connection and browser is available e The login data for direct access e g per CoL Certificate of License is available License number Delivery note number Note Hardware serial number Ensure that the serial number of the hardware displayed is the one you want to make the assignment f
6. 10 The following message briefly appears Starting software update Then the screen goes dark for several seconds 11 If a valid backup has been found the following message is output Do not operate or switch off until software update is finished If no valid backup was selected the upgrade is interrupted with the following message Image file is corrupt In this case switch off the control withdraw the data carrier and repeat the procedure by selecting a valid backup image 12 Wait until the following message appears Restoring complete Switch off and remove data medium 13 Switch the control off 14 Withdraw the storage medium from the slot at the front panel of the control 15 Switch the control on 16 The control boots normally Hardware and Software 38 Service Manual 03 2010 6 C5397 5DP20 0BAO Service cases software 3 3 Software backup Note If the procedure is interrupted then it must be restarted If the system CompactFlash Card is no longer identified as a bootable CompactFlash Card then a mini boot system must be generated on this card See also This is how you generate a mini boot system Page 44 In this case the license key of the system CompactFlash Card should be transferred to the control Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO 39 Service cases software 3 4 Software update 3 4 Software update 3 4 1 This is how you update the so
7. CU_LINK is not ready for operation e g after switching on 4 6 2 This is how you remove the NX10 The activities necessary when replacing an NX10 are subsequently described If the NX10 has a hardware defect then it must be replaced by an identical module Preconditions e The module is defective and must be replaced e The control cabinet is in a no voltage condition all of the connectors and cables are labeled Hardware and Software 106 Service Manual 03 2010 6FC5397 5DP20 0BA0 Service cases hardware Removing Hardware and Software 4 6 Expansion module NX10 X100 X103 DRIVE CLiQ interfaces X122 Digital inputs outputs X124 Electronic power supply RESET button T0 T2 Measuring sockets Type plate PE connection M5 3 Nm Figure 4 19 NX10 illustration NOTICE Electro static discharge ESD Before you touch the component discharge yourself at the cabinet or at the ground terminal Service Manual 03 2010 6FC5397 5DP20 0BAO 107 Service cases hardware 4 6 Expansion module NX10 Procedure 1 Switch off the control Completely switch off the system Check that the system is in a no voltage condition and is locked out so that it cannot be switched on again without the appropriate authorization 2 Access the control cabinet where the NX10 is located 3 Use a multimeter to check that the system really is in a no voltage condition
8. 6 C5397 5DP20 0BAO Service cases hardware 4 13 DMC20 4 13 DMC20 4 13 1 DMC20 status displays Status displays The DRIVE CLiQ Hub Module DMC20 has the following status displays which provide information about the module state LED Color State Description cause Remedy RDY Off Electronics power supply is missing or outside permissible tolerance range Green Continuous light The component is ready for operation and cyclic DRIVE CLiQ communication is taking place Orange Continuous light DRIVE CLiQ communication is being established Red Continuous light This component has at least one fault Remove and Note acknowledge fault The LED is controlled irrespective of the corresponding messages being reconfigured Green red Flashes at 0 5 Hz Firmware is being downloaded Flashes at 2 Hz Firmware download has been completed Wait Carry out a POWER ON for POWER ON Green orange_ Flashing Component recognition via LED is activated or red orange p0154 Note Both options depend on the LED status when activated via p0154 1 Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO 147 Service cases hardware 4 13 DMC20 4 13 2 DMC20 connections Connections X501 DRIVE CLIQ DRIVE CLiQ interfaces interfaces X500 X524 Electronics power supply LED Type plate Protective Shield connection conductor connec
9. Appendix B 2 Feedback on the documentation Hardware and Software 162 Service Manual 03 2010 6 C5397 5DP20 0BAO Appendix B 3 Documentation overview B 3 Documentation overview Documentation overview SINUMERIK 828D General documentation SINUMERIK a A GF Advertising Brochure EMC Directives User documentation ae ae a L IL SINUMERIK SINUMERIK SINUMERIK SINUMERIK 828D 828D 802D sl 828D 840D sl 840D sl 828D SINAMICS 840D sl 120 Operating Manual Programming manual Programming Manual Diagnostics Manual Turning Basic principles ISO Turning Milling Job planning ISO Milling Easy Screen Manufacturer service documentation SINUMERIK SINUMERIK SINUMERIK SINUMERIK 828D 828D 802D sl 828D 840D sl 828D SINAMICS 840D sl 120 Manual Function Manual Function Manual List Manual Commissioning Manual Basic Functions ISO Dialects Service Manual Extended Functions Electronic documentation Jil Ripe DOConCD Industry Mall DOConWEB Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO 163 Appendix B 3 Documentation overview Hardware and Software 164 Service Manual 03 2010 6 C5397 5DP20 0BAO Index B Backing up log files 17 C CompactFlash Card 151 Connections o ALM 130 DMC20 148 DMM 116 _ SLM 16kW 124 SLM 5kW 10kW 122 SMC30 140 o SME20 144 SME25 145 SMM 110 D Data backup 40 DC link cover flap 70 E EMC measures 153 End Use
10. Link Activitiy RDY NC CF Figure 4 2 Vertical flap detail The 3 LEDs located behind the protective flap on the front side of the PPU mean the following Name Color State Meaning RDY Green Is lit NC Ready and PLC in run mode Yellow Is lit Flashing PLC in stop mode Booting Red Is lit NC in stop mode e When booting if NC Ready is not yet available e Critical fault power off on necessary NC Yellow Cyclic flashing NC operation CF Yellow Is lit User CompactFlash Card being accessed CAUTION If the LED is lit the CompactFlash Card must not be removed Non compliance can result in damage to the CompactFlash Card Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO 71 Service cases hardware 4 1 PPU26x PPU28x LED status rear 72 The RJ45 socket is equipped with one green and one yellow LED As a consequence the following information of the PLC I O interface is displayed based on PROFINET Name Color State Meaning Link Green ON 100 MBit link available OFF Missing or faulty link Activity Yellow ON Sending or receiving OFF No activity FAULT Q SYNC O c pni O a a a Port 1 Port 2 Ethernet LAN X130 USB X135 X122 RS232 Figure 4 3 Rear of the PPU For diagnostic purposes the RJ45 sockets port 1 and port 2 are each equipped wit
11. Machine 2 Commissioning completed installed NOTICE Once saved data can no longer be changed Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO 63 Service cases software 3 7 Enter the final end user data EUNA 3 7 3 This is how you save the machine identity Saving the machine identity Note Ensure that the machine identity that has been entered is correct before saving in order that no incorrect information is saved In order to save the machine identity address data version data and logbook externally on a data carrier proceed as follows 1 Select the Diagnostics operating area N Diag nostics 2 Press the Version softkey ive Version 3 Press the Save softkey Save The Save version information Select Archive window opens Select a directory Hardware and Software 64 Service Manual 03 2010 6 C5397 5DP20 0BAO Service cases software Hardware and Software 3 7 Enter the tinal end user data EUNA 4 Press the OK softkey od The data are pre assigned so that a change is not necessary 04 21 09 MN sain 11 37 AM SINUMERIK 828D 828D TE81 ith NCU system sof a IN NF NN NO OEM applications Save version information name Hardware Figure 3 6 The Name text field is pre assigned as follows lt Machine name Number gt lt Number of the CompactFlash Card gt You now have the opportunity of changing
12. Machine data The following data are saved in the control in the Machine logbook e Contact data of the manufacturer OEM e Contact data of the dealer e Contact data of the end customer e Log of the service and diagnostic procedures that have already been carried out During a service call the data should be checked as to whether it is correct Open the Machine identity dialog box Procedure 1 Select the Diagnostics operating area N Diag nostics 2 Press the Version softkey to open the Version data dialog box jit Version 3 Press the Details softkey Details Hardware and Software 60 Service Manual 03 2010 6 C5397 5DP20 0BAO Service cases software 3 7 Enter the tinal end user data EUNA The data associated with the machine are displayed in the Machine logbook Machine logbook No Date Name Time Company department Error diagnostics measure Machine name no MILLING 388 Startup complete Machine installed Mes j Alarm F ANC PLC TE a sages ion ALY Tica MiB version 4 Press the Change softkey to open the Machine identity dialog box 5 Select the vertical softkey and enter the contact data of Manufacturer dealer and end customer Machine identity Serial number of CF card Machine name no MILLING 388 Machine type TYP 4711 v Custome
13. softkey to generate a new directory New The New Directory window opens 10 Enter the required name and confirm with OK a The directory is created subordinate to the selected folder 11 Press the OK softkey ES The Generate Archive Name window opens 12 Enter the required name and confirm with OK a A file with format type ard is saved in the selected directory Use Easy Archive data class archives All O Execute Control components MINE data IPLE data Ml Drive data ACX forme MIJHMI data Comment Created by Figure 3 1 Series commissioning Generating an archive 0 6FC5397 5DP20 0BAO 3 2 Series commissioning 25 Service cases software 3 2 Series commissioning 3 2 2 This is how you import a series commissioning archive from an external data carrier Reading in an archive from an external data carrier Procedure 1 Select the Start up operating area AS Start up 2 Press the menu forward key gt 3 Press the Series startup softkey Series al start u 4 Press OK v OK The Series Start up window opens 5 Activate Read in series startup 6 Press OK ov OK The Select Startup Archive window opens and the data tree is displayed Hardware and Software 26 Service Manual 03 2010 6 C5397 5DP20 0BAO Service cases software 3 2 Series commissioning 7 Select the required commissioning archive ARD Example U
14. the warning notice representing the highest degree of danger will be used A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage rsonnel The product system described in this documentation may be operated only by personnel qualified for the specific task in accordance with the relevant documentation for the specific task in particular its warning notices and safety instructions Qualified personnel are those who based on their training and experience are capable of identifying risks and avoiding potential hazards when working with these products systems Proper use of Siemens products Trademarks Note the following NWARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation If products and components from other manufacturers are used these must be recommended or approved by Siemens Proper transport storage installation assembly commissioning operation and maintenance are required to ensure that the products operate safely and without any problems The permissible ambient conditions must be adhered to The information in the relevant documentation must be observed All names identified by are registered trademarks of the Siemens AG The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights
15. 5DP20 0BAO 99 Service cases hardware 4 5 I O modules Removing 100 PLC I O Interface X2 an S1 H1 H6 Port2 Port1 jA X111 Grounding screw Figure 4 15 Rear of the PP 72 48D PN NOTICE Electro static discharge ESD Before you touch the module discharge yourself at the cabinet or at the ground terminal Procedure 1 Switch off the control Completely switch off the system Check that the system is in a no voltage condition and is locked out so that it cannot be switched on again without the appropriate authorization 2 Access the control cabinet where the module is located 3 Using a multimeter check the X1 power supply to ensure that the system really is in a no voltage condition If it has not already been done label all connectors that lead to the module now Only then can it be ensured that the cables are not interchanged 5 Withdraw the power supply X1 6 Release the connectors of the ribbon cables X111 X222 X333 on the module that are used to connect the digital inputs and outputs Remove the strain relief of the communication cables to interfaces X2 Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO Service cases hardware 4 5 I O modules 8 Remove the communication cables from interface X2 port 1 and port 2 9 Remove the ground connection by releasing the grounding screw 10 To remove the I O module release the fixing scre
16. 98 4 5 1 Status displays PP 72 48D PN ccciscsccccisseccece ives devtveccecetese n anian Nuen AR NNE ENNEA TEETAR 98 4 5 2 This is how you remove the PP 72 48D PN ssesessssnssennasnennanrennaneennnnnannaannnnantannanennnnnnannaanennaanan 99 4 5 3 This is how you install the PP 72 48D PN c cceecceeeeeeeeeeeeeseeeeeeeseneeeeeseeeeeeeseeeeeeeseeaeeeeennaees 107 4 5 4 Status displays PP 72 48D 2 2A PN cccccceceeeeeececeeceeeeeeececeaeeeeeeeeesedeceaeeeeeeeeesetenneeeeeeeenenea 102 4 5 5 This is how you remove the PP 72 48D 2 2A PN ccsccsscsssseeeceeseceeeaeceeeeeecseeecsecsesaeeaeeeteaees 103 4 5 6 This is how you install the PP 72 48D 2 2A PN ecccccccceccseeeeeeeeeeeeeeeeeeeseeeeeeeseneeeeeseneaeeeseneaees 105 4 6 Expansion module NX O ensanse iea a a A a estes A aai 106 4 6 1 Status displays on the NXI O sisisi nii aE E R 106 4 6 2 Thisis how you remove the NX10 cccicisccsncsdsccsssssuoiascsssasiadestsadesavacsndisiacedsasneaiaseatiunceauanatiibuns 106 AGS This is how you install the NX10 ices cic teecsitsinandhatessvstgasscrabaniansisceiacansedvidaasdeiorebiiceddaryatcrmnencuts 108 4 7 Single Motor Modules cccceeeeeeeeeeeeeeneee ee seeeee ee riti nnn innen EEan SN EAEE NENA AETERNE ERE 109 4 7 1 SMM istatus displays ersinnen a eE a Enae RAEE EEE EPAIA EARE TEREE RE 109 4 7 2 SU MIBe 8 Ute Coenen eine earn meee in a A O ES 110 4 7 3 This is how you remove a Motor MOdulle ci ccccccccsiciecccstisdeses
17. Overview The activities necessary when replacing the PP 72 48D 2 2A PN I O module are described in the following If the PP 72 48D 2 2A PN has a hardware defect then it must be replaced by an identical module Preconditions e The I O module is defective and must be replaced e The control cabinet is in a no voltage condition all of the connectors and cables are labeled Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO 103 Service cases hardware 4 5 I O modules Removing 104 PROFINET X2 Port 2 Port 1 wey aw X111 X3 Shield connection X333 Grounding screw Figure 4 18 Rear of PP 72 48D 2 2A PN NOTICE Electro static discharge ESD Before you touch the module discharge yourself at the cabinet or at the ground terminal Procedure 1 Switch off the control Completely switch off the system Check that the system is in a no voltage condition and is locked out so that it cannot be switched on again without the appropriate authorization 2 Access the control cabinet where the module is located 3 Using a multimeter check the X1 power supply to ensure that the system really is in a no voltage condition 4 Ifithas not already been done label all connectors that lead to the module now Only then can it be ensured that the cables are not interchanged 5 Withdraw the power supply X1 6 Release the connectors of the ribbon cables X111 X222 X333
18. Service Manual 03 2010 6FC5397 5DP20 0BAO 87 Service cases hardware 4 3 SINAUT modem 4 3 3 This is how you load the factory settings Loading the factory settings LM Supply connection for 24 V DC SIEMENS SET button for service functions Antenna connection LEDs 9 pin connector X1 RS232 socket SINAUT MD720 3 20 3AA00 Order number of the modem Figure 4 5 MD720 3 Front view If you press the SET key for longer than 4 seconds until the LED C starts to light up then the SINAUT MD720 3 configuration is reset to the default values set in the factory Paper clip SIEMENS 5 Figure 4 6 MD720 3 SET key Hardware and Software 88 Service Manual 03 2010 6FC5397 5DP20 0BA0 Service cases hardware 4 4 Machine control panels 4 4 1 Status displays MCP 310C PN LEDs for status display For the MCP 310C PN there are 3 LEDs in a row H1 H3 which provide information about the module state U S2 H1 H2 H3 Figure 4 7 Status displays 4 4 Machine control panels LED H1 green H2 green H3 red PowerOK PN Sync PN Fault Power Off off off off Power On voltage is stable on off off Boot software runs and loads the system software on on on System software runs on off off System software runs no
19. Web License Manager http www siemens com automation license NOTICE The NC start function is suppressed if a CNC option for which no valid license key has been entered is additionally activated This means that the machine can only operate on a severely restricted basis if an attempt is made to use an unlicensed CNC option 3 6 3 How to determine the license requirement Determining the license requirement Procedure 1 Press the All options softkey to list all the options that can be selected for this control 2 Activate or deactivate the required options in the Set column Mark the checkbox Enter the number of options Options displayed in red are activated however are not licensed or insufficiently licensed OR Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO 53 Service cases software 3 6 Licensing 3 6 4 Licensing All options Option Additionally 1 axis spindle 6FC5888 8AABB BYBB 3 Press the Missing licenses softkey to display all options that are activated but not licensed In the Set column you can deselect the options that you do not require All options 1 positioning axis auxiliary spindle in addition 1 1 Tena ee fr ith force control 6FC5886 6AM61 BYBA O licenses f BFOBBBB MMBZ AYRA Er pena z j E ann 27 YB Ss transformation BFCSOO0 ONTISS AYBO AE mra aa TaT ete
20. been completed Wait for POWER ON Carry outa POWER ON Green orange or red orange Flashing Component recognition via LED is activated p0144 Note Both options depend on the LED status when module recognition is activated via p0144 1 OUT gt 5V OFF Electronics power supply is missing or outside permissible tolerance range Power supply lt 5 V Orange Continuous light Electronics power supply for measuring system available Power supply gt 5 V Notice It must be ensured that it is permissible to operate the connected encoder with a 24 V power supply If an encoder that is designed for a 5 V supply is operated with a 24 V supply this can destroy the encoder electronics Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO 139 Service cases hardware 4 11 SMC20 SMC30 4 11 6 SMC30 connections Connections 1 Press lug downwards X500 DRIVE CLiQ interface X524 Electronics power supply LEDs X520 Encoder system interface HTL TTL with track monitoring SSI Alternative encoder X521 system interfaces HTL TTL with track monitoring SSI X531 Shield Protective ground connection connection M4 1 8 Nm Figure 4 27 Connections SMC30 4 11 7 This is how you remove an SMC30 Overview The activities that must be taken into account when replacing an SMC30 are subsequently described
21. communication to the on off off controller System software runs communication to the on on off controller STOP state System software runs communication to the on Flashes at off controller RUN state 0 5 Hz Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 89 Service cases hardware 4 4 Machine control panels 4 4 2 This is how you remove the MCP 310C PN Overview The activities that must be taken into account when replacing a machine control panel are subsequently described If the machine control panel has a hardware defect then it must be replaced by an identical replacement part Preconditions e The module is defective and must be replaced e The control cabinet is in a no voltage condition all of the connectors and cables are labeled Hardware and Software 90 Service Manual 03 2010 6 C5397 5DP20 0BAO Service cases hardware Removing 4 4 Machine control panels SIEMENS om N ge Brasem NCH TVR PH AOE oO eras tet w mcns SAD ORAS v masua O nimeer omus P E ienne men a CE i MAC 08 00 06 73 C2 46 aT Slot for Emergency Stop button or spindle override Power supply interface Handwheel connection Handwheel connection Switch for SINUMERIK 828D no function Switch LEDs Ethernet cable strain relief Port 2 PLC I O interfaces based on PROFINET Port 1 PLC I O interfaces based on PROFINET Equipotential bonding Feedrate override Custome
22. corresponding messages being reconfigured Green Firmware is being downloaded Red 0 5 Hz Green red 2 Hz Firmware download has been completed Wait for Carry outa POWER POWER ON ON Green orange or Component recognition via LED is activated p0124 red orange Note Both options depend on the LED status when module recognition is activated via p0124 1 Z N DANGER DC link voltage Irrespective of the state of LED DC Link a hazardous DC link voltage can always be present The warning information on the components must be carefully observed Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 129 Service cases hardware 4 10 Active Line Modules 4 10 2 ALM connections Connections X21 Terminals X200 X202 X24 24 V terminal adapter Unlocking Protective cover Electronics power P 4 supply Va 0 5 x 3 5 DC link busbars Protective cover LEDs X1 Line connection Protective conductor connection M5 3Nm Shield plate Figure 4 24 ALM connections Hardware and Software 130 Service Manual 03 2010 6FC5397 5DP20 0BA0 Service cases hardware 4 10 3 Overview Removing Hardware and Software 4 10 Active Line Modules This is how you remove an ALM The activities that must be taken into account when replacing an Active Line Module ALM are subsequently described I
23. for tool offsets TM Tool Management TMMG Tool Magazine Management Hardware and Software 156 Service Manual 03 2010 6FC5397 5DP20 0BA0 Appendix B 1 List of abbreviations Abbreviation Meaning Explanation WCS Workpiece Coordinate System WO Work Offset ZOA Zero Offset Active Identifier file type for work offset data Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO 157 Appendix B 7 List of abbreviations Hardware and Software 158 Service Manual 03 2010 6FC5397 5DP20 0BAO Appendix B 2 Feedback on the documentation B 2 Feedback on the documentation This document will be continuously improved with regard to its quality and ease of use Please help us with this task by sending your comments and suggestions for improvement via e mail or fax to E mail mailto docu motioncontrol siemens com Fax 49 9131 98 2176 Please use the fax form on the back of this page Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO 159 Appendix B 2 Feedback on the documentation Hardware and Software 160 Service Manual 03 2010 6 C5397 5DP20 0BAO Appendix B 2 Feedback on the documentation To From SIEMENS AG Name I DT MC MS1 D 91050 Erlangen Germany Zip code City Fax 49 9131 98 2176 Documentation Fax Suggestions and or corrections Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO 161
24. is shown in white in the following diagram L a TLP 3 Insert the SIM card into the upper section of the SIM card holder so that the contact surface is at the bottom and the sloped corner of the SIM card points towards the front of the device 4 Insert the SIM card far enough so that the upper section of the SIM card holder can again be flipped downwards Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 85 Service cases hardware 4 3 SINAUT modem 5 Press the upper section of the SIM card holder downwards Ensure that the sloped corner of the SIM card clicks into place au 6 Using your fingernail or a suitable object slide the upper section of the SIM card holder approximately 2 mm in the direction of the arrow to the right in order to lock the SIM card holder i gt brett i Fy amp j LL PES ERE E wey o Hive p LL PEL GEEEE Hardware and Software 86 Service Manual 03 2010 6FC5397 5DP20 0BAO Service cases hardware 4 3 SINAUT modem 8 Then assemble the two housing sections again To do this locate the printed circuit board in the upper and lower rails inside the rear section of the housing Railfor the printed circuit board 9 Press the two housing sections together so that the lugs of the fasteners click into place at the top and bottom Result SIM card is ready screw the SINAUT modem together again Hardware and Software
25. isolated from the supply 4 Open the cover cap of the NX10 module o gt NQ If it has not already been done label all connectors and cables that lead to the module now Only then can it be ensured that the cables are not interchanged Withdraw the electronics power supply X124 Withdraw the digital input output terminal X122 Withdraw any connected DRIVE CLiQ cables X100 X103 Remove the protective conductor connection of the NX10 0 Release the screws retaining the NX10 to the mounting plate OR 11 If the module is located to the left of the infeed remove the module by first pulling it upwards and then removing it towards the left 4 6 3 This is how you install the NX10 Installing Procedure 1 OMNDAA AR w Screw the new NX10 to the mounting plate OR If the module was located to the left of the infeed re attach it here by first introducing the NX10 into the holder to the right and then press it down slightly to retain it Reconnect the protective conductor connection of the NX10 Insert the DRIVE CLiQ cables that were previously withdrawn into sockets X100 X103 Insert the digital input output terminal X122 into the NX10 Reconnect the electronics power supply X124 Now check that all of the cables have been re connected Now close the cover cap of the NX10 Close the cabinet and switch on the system again CAUTION Ensure that all of the connector
26. of the owner Disclaimer of Liability We have reviewed the contents of this publication to ensure consistency with the hardware and software described Since variance cannot be precluded entirely we cannot guarantee full consistency However the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions Siemens AG order number 6FC5397 5DP20 0BA0 Copyright Siemens AG 2010 Industry Sector 04 2010 Technical data subject to change Postfach 48 48 90026 N RNBERG GERMANY Preface SINUMERIK documentation Target group Benefits Standard version Hardware and Software The SINUMERIK documentation is organized in three parts e General documentation e User documentation e Manufacturer service documentation Information on the following topics is available under the link http www siemens com motioncontrol docu e Ordering documentation Here you can find an up to date overview of publications e Downloading documentation Links to more information for downloading files from Service amp Support e Researching documentation online Information on DOConCD and direct access to the publications in DOConWEB e Customizing documentation based on Siemens content using My Documentation Manager MDM http www siemens com mdm e My Documentation Manager provides you with a range of features for generating your own machine documentation e Traini
27. off off mcp pn64 For SINUMERIK 828D the IP address 192 168 214 64 must always be assigned to the MCP 4 4 4 Status displays MCP 483C PN LED status displays For the MCP 483C PN there are 3 LEDs in a row H1 H3 which provide information about the module state SIEMENS 00 amay SANUMERIK MCP 483C IE TA 0 59 C SUPPLY 24VOC 22A its 24VDC OJA Digital Output MANE IP GFCSIO2 0AF22 0AAD e ET TT Bos Saanman momma WILLE hinn cE MORNIN version A S2 H1 H2 H3 WarusiY Figure 4 10 Status displays Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 93 Service cases hardware 4 4 Machine control panels 4 4 5 Overview 94 LED H1 green H2 green H3 red PowerOK PN Sync PN Fault Power Off off off off Power On voltage is stable on off off Boot software runs and loads the system software on on on System software runs on off off System software runs no communication to the on off off controller System software runs communication to the on on off controller STOP state System software runs communication to the on Flashes at off controller RUN state 0 5 Hz This is how you remove the MCP 483C PN The activities that must be taken into account when replacing a machine control panel are subsequently described If the machine control panel has a hardware defect then it must be replaced by an identical replacement pa
28. the Chapter Service functions LED status 4 3 SINAUT modem The device has 3 LEDs which provide information about the operating state SIEMENS S Status Q Quality C Connect LED State Meaning S Q C Common Flash on and off in a fast sequence Booting Slow flashing in synchronism Service mode Flash on and off in a slow sequence Update Fast flashing in synchronism Error Flashes 1 time with interval Flashes 2 times with interval Flashes 3 times with interval S Status Slow flashing Waiting for PIN input Fast flashing PIN error SIM error Q Quality Slow flashing Logging into GSM network Field strength inadequate Field strength adequate Field strength good Always ON Field strength very good OFF Waiting for PIN C Connect Flashing Terminal mode activated Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 81 Service cases hardware 4 3 SINAUT modem 4 3 2 This is how you insert the SIM card CAUTION Risk of damage to sensitive components due to static electricity This activity must always be carried out by trained personnel Open the module Proceed as follows to open the module 1 Ensure that the module has been disconnected from the power supply 2 You must open the housing of the SINAUT MD720 3 in order to insert the SIM card A fastener with opening lug is located at the upper and lower side of the housing 720 3400 Op
29. the electrical system must be performed after the system has been switched off and disconnected from the power supply N DANGER Proper transportation expert storage installation and mounting as well as careful operation and maintenance are essential for this SINUMERIK device to operate correctly and reliably The details in the catalogs and proposals also apply to the design of special equipment versions In addition to the danger and warning information provided in the technical customer documentation the applicable national local and system specific regulations and requirements must be taken into account Only class DVC A protective extra low voltages PELVs may be connected to connections and terminals up to 60 V DC in accordance with EN 61800 5 1 Should it be necessary to test or take measurements on live equipment then the specifications and procedural instructions defined in Accident Prevention Regulation BGV A2 must be adhered to in particular 8 Permissible deviations when working on live components Suitable electric tools should be used Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 11 Safety notes 12 Z N WARNING Operating the equipment in the immediate vicinity lt 1 5 m of mobile telephones with a transmitting power of gt 1 W may lead to incorrect functioning of the devices Connecting cables and signal lines should be installed in such a way that in
30. 200 X203 DRIVE CLIQ 4208 ray VE Logg X200 yey Unlocking Protective cover A Electronics power E O om supply O n 24 V jumper plug zZ 1 0 5 x 3 5 gt ier under the protective cover lt x Protective cover g wE DC link DY omni o busbars CE Gu LEDs GE SIEMENS Type plate i X2 Motor connection Protective conductor X1 connection 3 Motor connection M5 3Nm Figure 4 21 Double Motor Module DMM 116 Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO Service cases hardware 4 8 3 Overview Removing Hardware and Software 4 8 Double Motor Modules This is how you remove a Motor Module The activities required when replacing a Motor Module are subsequently described If a Motor Module has a hardware defect then it must be replaced by an identical module Preconditions e The module is defective and must be replaced e The control cabinet is in a no voltage condition all of the connectors and cables are labeled NOTICE Electro static discharge ESD Before you touch the module discharge yourself at the cabinet or at the ground terminal Procedure 1 Switch off the control Completely switch off the system Check that the system is in a no voltage condition and is locked out so that it cannot be switched on again without the appropriate authorization 2 Access the control cabinet where the infeed module is located 3 If it has not already been done label
31. 397 5DP20 0BA0 Service cases hardware 4 8 Double Motor Modules 13 Release the screws that are used to retain the motor module to the mounting plate 14 Remove the protective conductor connection of the Motor Module 15 Remove the Motor Module from the control cabinet 4 8 4 This is how you install a Motor Module Installing N DANGER Risk of electric shock A hazardous voltage is present for up to 5 minutes after the power supply has been switched off The protective cover must not be opened until this time has elapsed The warning information on the components must be carefully observed Procedure 1 Screw the new Motor Module to the mounting plate 2 Reconnect the protective conductor connection of the Motor Module 3 Open the protective cover of the DC link voltage using a suitable tool e g a screwdriver 4 Release the Torx screws and connect the DC link busbar L Torx T20 Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 119 Service cases hardware 4 8 Double Motor Modules 120 5 Tighten the Torx screws of the DC link busbars observe the correct sequence amp Torx T20 amp Torx T20 6 Place the red jumper plug on the electronics busbar until it clicks into place 7 Place the 24 V terminal adapter on the electronics power supply busbar until it clicks into place 8 Close the protective cover of the DC link voltage 9 Reconnect mot
32. 4 21 09 11 10 AN Machine Axis Drive Motor Index Name Type No Identifier Type Channel 1 MXI Linear CHAN1 2 MZ Linear CHAN1 3 MSPI Save data CHAN 4 MSP2 CHAN1 5 MB1 The data have been backed up successfully CHAN1 6 MSP3 CHAN1 7 MM CHAN1 Current access level Manufacturer 6 Confirm this message with OK eos OK NOTICE While the data is being backed up the control system must neither be operated nor turned off Hardware and Software 20 Service Manual 03 2010 6FC5397 5DP20 0BAO Service cases software 3 1 Backing up user data 3 1 2 This is how you load the user data backup NOTICE If this function is activated the actual system data is replaced by the data backup Procedure Proceed as follows to load the internal data backup 1 The following display is shown when booting after power on Press SELECT key to enter setup menu 2 To start the Setup menu press the lt SELECT gt key You now go to the Setup menu Startup menu Reload saved user data Normal system startup Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO 21 Service cases software 3 1 Backing up user data 3 Using the arrow key select the menu item Reload saved user data Setup menu Normal startup Load user data that have been saved before 4 Confirm that the backup is loaded by pressing the key lt INPUT gt
33. 6 C5397 5DP20 0BAO Service cases software 2 Press the lt SELECT gt key Normal startup is the default setting 3 Now press the following keys in succession Menu reset key HSK2 horizontal SK2 VSK2 vertical SK2 T a E a Lal v 4 The setup menu is displayed Normal system startup Startup menu 3 O Reload saved user data Install software update backup O Create software backup NCK default data gt Drive default data O PLC default data HMI default data Factory settings Delete OEM data gt PLC Stop 3 4 Software update 5 Use the cursor keys to select the menu item Install software update backup 6 Press the lt INPUT gt key to confirm your selection Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO 41 Service cases software 3 4 Software update 7 Use the cursor keys to select Yes Setup menu Normal startup Reload saved user data Install software update C3 Do you want to install the software update Then insert your CF card or USB Stick and press yes Factory settinas Delete OEM data PLC Stop Installs a software update backup image 8 Select the update image tgz on the storage medium and confirm with lt INPUT gt Install software update backup Software images 828d_image tgz oO Press SELECT to refresh list of software images 2 Press INPUT to
34. 6 Service Manual 03 2010 6FC5397 5DP20 0BA0 Service cases hardware 4 9 Smart Line Modules 4 9 6 This is how you install an SLM Installing Z N DANGER Risk of electric shock A hazardous voltage is present for up to 5 minutes after the power supply has been switched off The protective cover must not be opened until this time has elapsed The warning information on the components must be carefully observed Procedure 1 Screw the new module to the mounting plate 2 Reconnect the protective conductor connection of the module 3 Open the protective cover of the DC link voltage using a suitable tool e g a screwdriver 4 Release the Torx screws and connect the DC link busbar 5 Tighten the Torx screws of the DC link busbars observe the correct sequence 6 Place the red jumper plug on the electronics busbar until it clicks into place Observe the sequence when tightening Torx T20 1 8 Nm 7 Place the 24 V terminal adapter on the electronics power supply busbar until it clicks into place 8 Close the protective cover of the DC link voltage Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 127 Service cases hardware 4 9 Smart Line Modules 9 Reconnect the line supply connection X1 at the module 10 Insert the DRIVE CLiQ cables that were previously withdrawn into sockets X200 X202 11 Reinsert the enable terminals X21 at the module 12 Check whet
35. EE EE heeded eaaa ea eee 13 2 1 System OVENI OW asaina E R EE E ipeeuzihanedenteateeantes 13 2 2 System varion S enaa E AN 14 3 Service Cases software sssssesssesesernseresnrestrnnertnnnstrnnerttanaeotnnneretnnnetnaseretnnnsenaneeeannetnanereenneeennneeenn 17 3 1 Backing up user data 0 eee ee eee eee erent ee errr ee ete ee SEEE e ee eee ne ee eet ne ee ee naneee ee naaeee ee saaeeeeenaaeeeee 18 3 1 1 This is how you backup user data eee cece ee eeeneeeeeeeeeeeceeeaeeeeeeeaeeeeeeaaeeeeeeaeeeeeeaeeeeeenaeeeeeaaas 18 3 1 2 This is how you load the user data DACKUD ecceeeceeeeeeeceeeeeeeeeaeeeeeeaaeeeseeaaeeeeeeaeeeesenaeeeeseaes 21 3 2 Series COMMISSIONING 2 esis eccsccceccecedec ede aces dace des EEEE EEEIEE EE EE TENERE 23 3 2 1 This is how you generate a series commissioning archive on an external data carrier 23 3 2 2 This is how you import a series commissioning archive from an external data carrier 26 3 2 3 This is how you generate a series commissioning archive on the system CompactFlash Ca eaaa cosas ccd aweee A debuts civ inane semen pecan ah piesa seeeeenteaedien alates Geen S 27 3 2 4 This is how you import a series commissioning archive from the system CompactFlash CONG E nis A E E chee dade ies egdteeseedecdivaviaueschvcadeeuneboce E E 29 3 3 SoftWare ack Deseuse nna i dee tees casa beeen ey edi ate ec a Medaan essed aaaea evar ees 32 3 3 1 This is how you generate a software DACKUP
36. F Electronics power supply is missing or outside permissible tolerance range Green Continuous light The component is ready for operation and cyclic DRIVE CLiQ communication is taking place Orange Continuous light DRIVE CLiQ communication is being established Red Continuous light This component has at least one fault Remove and Note acknowledge fault The LED is controlled irrespective of the corresponding messages being reconfigured Green red Flashes at Firmware is being downloaded 0 5 Hz Flashes at 2 Hz Firmware download has been completed Carry outa POWER ON Wait for POWER ON Green orange or Flashing Component recognition via LED is activated red orange p0144 Note Both options depend on the LED status when module recognition is activated via p0144 1 Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO 135 Service cases hardware 4 11 SMC20 SMC30 4 11 2 SMC20 connections Connections X500 DRIVE CLIiQ interface X524 Electronics power SSS supply LED X520 Encoder system interface vO Protective ground connection WA M4 1 8 Nm Figure 4 25 Connections SMC20 4 11 3 This is how you remove an SMC20 Overview The activities that must be taken into account when replacing an SMC20 are subsequently described If aSMC20 has a hardware def
37. If an SMC30 has a hardware defect then it must be replaced by an identical module Hardware and Software 140 Service Manual 03 2010 6FC5397 5DP20 0BA0 Service cases hardware 4 11 SMC20 SMC30 Preconditions e The module is defective and must be replaced e The control cabinet is in a no voltage condition all of the connectors and cables are labeled Removing 2 Swivel the module to the front esses Mounting slide Rotate a screwdriver with a wide blade 5 to 8 mm G in the slot of the mounting slide through 90 or amp alternatively press the lug downwards Figure 4 28 SMC30 removal NOTICE Electro static discharge ESD Before you touch the module discharge yourself at the cabinet or at the ground terminal Procedure 1 Before withdrawing it label the connector X524 for the electronics power supply 2 Screw on the encoder connecting cable to X520 or X521 X531 if required also the shield connection 3 Release the protective conductor connection and write the position designation on the cable Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO 141 Service cases hardware 4 11 SMC20 SMC30 4 11 8 Installing 142 4 Slide the lug downwards 5 Swivel the module to the front to remove it CAUTION The 50 mm clearances above and below the components must be observed This is how y
38. M data PLE Stop Create a software backup image on a user medium Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0OBAO 33 Service cases software 3 3 Software backup 11 Press the lt INPUT gt key to start the backup The software first checks whether a backup was already generated on the card and outputs a message The backup can now be overwritten or the process interrupted by making the appropriate operator action 12 When starting to generate a backup the following message is output Startup menu Normal startup Reload saved user data Creating SW backup archive Creating system card image 35 MB HMI default data Factory settings Delete OEM data PLC Stop Create a software backup image on a user medium 13 Wait until the following message is displayed Startup menu Normal startup Reload saved user data Creating SW backup archive Archive created Remove the user CF card or USB stick and power on off the control HMI default data Factory settinas Delete OEM data PLC Stop Create a software backup image on a user medium Hardware and Software 34 Service Manual 03 2010 6 C5397 5DP20 0OBAO Service cases software 3 3 Software backup 14 Withdraw the storage medium from the slot at the front panel of the control 15 Switch the control off 16 Switch the control on 17 The control boo
39. SIEMENS SINUMERIK SINUMERIK 828D Hardware and Software Service Manual Valid for CNC software for SINUMERIK 828D V2 6 03 2010 6FC5397 5DP20 0BAO Preface Safety notes System description Service cases software Service cases hardware Spare parts and accessories ESD guidelines Appendix wir oa A o IN Legal information Warning notice system Qualified Pe This manual contains notices you have to observe in order to ensure your personal safety as well as to prevent damage to property The notices referring to your personal safety are highlighted in the manual by a safety alert symbol notices referring only to property damage have no safety alert symbol These notices shown below are graded according to the degree of danger NDANGER indicates that death or severe personal injury will result if proper precautions are not taken NWARNING indicates that death or severe personal injury may result if proper precautions are not taken NCAUTION with a safety alert symbol indicates that minor personal injury can result if proper precautions are not taken CAUTION without a safety alert symbol indicates that property damage can result if proper precautions are not taken NOTICE indicates that an unintended result or situation can occur if the corresponding information is not taken into account If more than one degree of danger is present
40. SINUMERIK 828D then this CNC option must be licensed at the machine and is only valid for this CompactFlash Card Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO 51 Service cases software 3 6 Licensing 52 Proceed as follows to access the licenses dialog box 1 Select the Start up operating area AS Start up 2 Press the menu forward key Ed 3 Press the Licenses softkey a Lic The Licensing window opens Using the vertical softkeys you can execute the following actions Serial number of CF card 00000000000000000 Hardware type SINUMERIK 8280 Here you can enter a new license key B Licensing Display a serial number Overview Display all options Display Missing licenses Exp license requirement Read in the license key Overview po requirement license key Series a License Key is sufficient Figure 3 3 Licensing Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 Service cases software 3 6 Licensing Web License Manager Licenses that are purchased are assigned via the Internet By using the Web License Manager you can assign licenses to hardware in a standard Web browser To conclude the assignment the license key must be entered at the control via the user interface See also The license database administered by Siemens can only be accessed using the
41. SR 154 B APPONODG arnon a E AS 155 B 1 List OF abbreviations misongis aea a a aaa EE aaa aaa aa 155 B 2 Feedback on the documentation c cececeeecceceeeeeeeeeeaaeceeeeeeeseceaaeceeeeeeeseccncaeeeeeeesessesaaeeneess 159 B 3 DOCUMENTATION OvervieW sieren diinsiin naa apaia anaa aa a aa aiaiai iiaa 163 MAER aeren Raa a A a a ce ote Eaa E a E ea e aa aa ea EE 165 Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 9 Table of contents 10 Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO Safety notes 1 The following notices are intended firstly for your personal safety and secondly to prevent damage occurring to the product described or any connected devices and machines Non observance of the warnings can result in severe personal injury or property damage N DANGER Only appropriately qualified personnel may commission start up SINUMERIK equipment The personnel must take into account the information provided in the technical customer documentation for the product and be familiar with and observe the specified danger and warning notices When electrical equipment and motors are operated the electrical circuits automatically conduct a dangerous voltage When the system is operating dangerous axis movements may occur throughout the entire work area A potential fire hazard exists due to the energy being transferred in the equipment and the work materials used All work on
42. VE CLiQ interface Figure 4 31 Connections SME25 Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BAO 145 Service cases hardware 4 12 SME20 SME25 4 12 4 Overview Removing Installing 146 This is how you remove an SME25 and install it again The activities that must be taken into account when replacing an SME25 are subsequently described If an SME25 has a hardware defect then it must be replaced by an identical module Preconditions e The module is defective and must be replaced e The control cabinet is in a no voltage condition all of the connectors and cables are labeled NOTICE Electro static discharge ESD Before you touch the module discharge yourself at the cabinet or at the ground terminal Procedure 1 Release the encoder connecting cable of the SME25 2 Withdraw the DRIVE CLiQ cable from the SME25 3 Release the protective conductor connection of the SME25 4 Remove the defective SME25 Procedure 1 Now install the new SME25 2 Screw on the protective conductor connection 3 Reconnect the encoder connecting cable 4 Connect the DRIVE CLiQ cable CAUTION Cables The maximum DRIVE CLiQ cable length is 100 m The maximum encoder cable length is 3 m In order to guarantee the degree of protection all of the plug connectors must be correctly screwed into place or snapped into place Hardware and Software Service Manual 03 2010
43. acing an SME20 are subsequently described If an SME20 has a hardware defect then it must be replaced by an identical module Preconditions e The module is defective and must be replaced e The control cabinet is in a no voltage condition all of the connectors and cables are labeled Removing NOTICE Electro static discharge ESD Before you touch the module discharge yourself at the cabinet or at the ground terminal Hardware and Software 144 Service Manual 03 2010 6FC5397 5DP20 0BAO Service cases hardware 4 12 SME20 SME25 Procedure 1 Installing Release the encoder connecting cable of the SME20 2 Withdraw the DRIVE CLiQ cable from the SME20 3 4 Remove the defective SME20 Release the protective conductor connection of the SME20 Procedure 1 Now install the new SME20 2 Screw on the protective conductor connection 3 4 Connect the DRIVE CLiQ cable Reconnect the encoder connecting cable CAUTION Connections cables Only measuring systems where the measuring system power supply is not grounded may be connected The maximum DRIVE CLiQ cable length is 100 m The maximum encoder cable length is 3 m In order to guarantee the degree of protection all of the plug connectors must be correctly screwed into place or snapped into place 4 12 3 SME25 connections Connections Encoder system Protective ground connection interface M4 1 8Nm 17 pole DRI
44. all connectors and cables that lead to the module now Only then can it be ensured that the cables are not interchanged 4 Withdraw the enable terminals X21 and X22 if available 5 Withdraw the connected DRIVE CLiQ cables X200 X202 6 Release the fixing screw Torx and remove the motor connection X1 and X2 if available Z N DANGER Risk of electric shock A hazardous voltage is present for up to 5 minutes after the power supply has been switched off The protective cover must not be opened until this time has elapsed The warning information on the components must be carefully observed 7 Open the protective cover of the DC link voltage of the defective module as well as the adjacent module if available using a suitable tool e g a screwdriver 8 Withdraw the 24 V terminal adapter Service Manual 03 2010 6FC5397 5DP20 0BA0 117 Service cases hardware 4 8 Double Motor Modules 9 Using a multimeter set the measuring range to 1000 V DC at the points DCP DCN check that the DC link voltage is in a no voltage condition Only continue with the work when it has been absolutely ensured that no voltage is present a no voltage condition has been established 10 Withdraw the red 24 V jumper plug 11 Release the Torx screws of the DC link f if L Torx 720 K Torx T20 12 Open the DC link busbars of the two modules Hardware and Software 118 Service Manual 03 2010 6FC5
45. an internal data backup see also This is how you backup user data Page 18 A correct complete backup is only generated using the internal data backup 3 Switch the control off 4 Switch on the control again as the backup can only be generated when the control boots After the control has been switched on the following display appears O Press SELECT key to enter setup menu _ o o o 5 Press the lt SELECT gt key Normal startup is the default setting 6 Now press the following keys in succession Menu reset key HSK2 horizontal SK2 VSK2 vertical SK2 a y Hardware and Software 32 Service Manual 03 2010 6FC5397 5DP20 0BA0 Service cases software 3 3 Software backup 7 The Startup menu is displayed Startup menu Reload saved user data Install software update backup O Create software backup O NEK default data Drive default data PLC default data HMI default data Factory settings O Delete OEM data PLC Stop Normal system startup 8 Using the cursor keys select the menu item Create software backup 9 Press the lt INPUT gt key to confirm your selection 10 Insert a storage medium into the slot on the front panel Startup menu O Normal startup Reload saved user data Creating SW backup archive Please insert user CF card or USB stick to save backup file To continue press INPUT Factory settings Delete OE
46. ator panel by releasing the clips 17 Remove the system CompactFlash Card from the control refer to Chapter This is how you remove the system CompactFlash Card Page 76 This is how you install the PPU Procedure 1 Now install the system CompactFlash Card into the new PPU refer to Chapter This is how you insert the system CompactFlash Card Page 78 Installing a new PPU Attach and tighten the clips to fix the PPU Connect the ground connections and tighten Insert the PN1 PN2 interfaces that were withdrawn Insert the Ethernet cable that was withdrawn at X130 Insert the DRIVE CLiQ cable that was withdrawn at X100 X102 Insert the USB cable that was withdrawn at X135 9 Insert the handwheel terminal that was withdrawn at X142 10 Insert the digital input output terminals that were withdrawn at X122 X132 X142 11 Reconnect power supply X1 oN DOO A ODN 12 Retighten the strain relief assemblies 13 Close the cabinet and switch on the system again 14 Read in the available data backup Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO Service cases hardware 4 1 PPU26x PPU28x Note Changing the MAC address When replacing the PPU then the MAC address of Ethernet interface X130 changes Notify the customer or the system administrator of the new MAC address N CAUTION Ensure that all of the connectors and screws are correctly tightened or latched and inserted
47. carrier Hardware and Software Procedure 1 Select the Start up operating area Start up 2 Press the menu forward key 7 3 Press the Series startup softkey Series gl start u Service Manual 03 2010 6FC5397 5DP20 0BA0 23 Service cases software 3 2 Series commissioning 4 Activate Series startup The Create Series Startup window opens Create series start up Use Easy Archive data class archives All O Execute Control components M PLC data Drive data ACX format binary O ASCII format HMI data Comment Created by Series e Li Sca censes 5 Select the desired control components Note Easy Archive e Select all of the components unless it is known that individual components do not deviate from the Siemens standard e Select all data classes unless only certain data e g INDIVIDUAL are to be backed up 6 Press the Generate archive softkey archive The Generate Archive Select Archive window opens 7 Select the storage location of the archive USB USB FlashDrive at the rear slot X135 USER USB USB FlashDrive in slot X125 at the front User CF CompactFlash Card in the slot at the front Hardware and Software 24 Service Manual 03 2010 6 C5397 5DP20 0OBAO Service cases software Hardware and Software Service Manual 03 201 8 Select a directory Example User CF OR 9 Press the New directory
48. ce cases hardware 4 10 Active Line Modules 9 Using a multimeter set the measuring range to 1000 V DC at the points DCP DCN check that the DC link voltage is in a no voltage condition Only continue with the work when it has been absolutely ensured that no voltage is present no voltage condition has been established 10 Withdraw the red 24 V jumper plug 11 Release the Torx screws of the DC link Torx T20 12 Open the DC link busbars of the two modules 13 Release the screws that are used to retain the module to the mounting plate 14 Remove the protective conductor connection of the module 15 Remove the module from the control cabinet Hardware and Software 132 Service Manual 03 2010 6FC5397 5DP20 0BA0 Service cases hardware 4 10 Active Line Modules 4 10 4 This is how you install an ALM Installing Z N DANGER Risk of electric shock A hazardous voltage is present for up to 5 minutes after the power supply has been switched off The protective cover must not be opened until this time has elapsed The warning information on the components must be carefully observed Procedure 1 Screw the new module to the mounting plate 2 Reconnect the protective conductor connection of the module 3 Open the protective cover of the DC link voltage using a suitable tool e g a screwdriver 4 Release the Torx screws and connect the DC link busbar 5 Tighten the Torx screws
49. condition and is locked out so that it cannot be switched on again without the appropriate authorization 2 Access the operator panel control cabinet in which the machine control panel is located 3 Using a multimeter check the X10 power supply to ensure that the system really is in a oN OD ON 9 no voltage condition If it has not already been done label all connectors that lead to the module now Only then can it be ensured that the cables are not interchanged Withdraw the power supply X10 Release the strain relief of the Ethernet cable Remove the Ethernet cables from the X20 X21 interface port 1 port2 Release other cables e g the Emergency Stop cable or the button from the mini handheld unit or from other command devices if available Remove the ground connection by releasing the grounding screw 10 Release the machine control panel from the control panel by releasing the clips 11 Note down the set address S2 at the DIL switch of the defective module 4 4 6 This is how you install the MCP 483C PN Installing Procedure Oop Oe ON 96 Set DIL switch S2 of the new module to what you previously noted down Installing a new machine control panel Secure the clips to retain the machine control panel and tighten them Connect the ground connection Reconnect the other cables e g the Emergency Stop cable or the button from the mini ha
50. continue with selected software image Installs a software update backup image Hardware and Software 42 Service Manual 03 2010 6 C5397 5DP20 0BAO Service cases software Hardware and Software 3 4 Software update 9 The software update is started The following message appears while the update is running Do not operate or switch off until software update is finished 10 Wait until the following message is output Restoring complete Switch off and remove data medium 11 Withdraw the storage medium from the slot 12 Switch the control off 13 Switch the control on 14 The control boots normally NOTICE If the update is interrupted then it must be restarted If the system CompactFlash Card is no longer identified as bootable system then a mini boot system must be generated on this card see also This is how you generate a mini boot system Page 44 In this case the license key of the system CompactFlash Card should be transferred to the control Service Manual 03 2010 6FC5397 5DP20 0BA0 43 Service cases software 3 5 Mini boot system on the CompactFlash Card 3 5 Application Mini boot system on the CompactFlash Card If the system CompactFlash Card hardware is defective then it must be replaced The replacement card is an empty CompactFlash Card without any system software and without any user software and cannot be used as system CompactFlash Card as it i
51. cssscareasedtvssnssansesanadeseannsadensanddtienasd 111 4 7 4 This is how you install a Motor Module i iiss ccctasicdieessiasuseaseduinspttudeenavncwsedabihedaaaasndlincetvadseantnceuenaxs 113 4 8 Double Motor Modul seiras aaa AA AEE eden A E 115 4 8 1 DMM stat s displays s ssiinsin sta lidar edltnetatontatiniasaidiasiucnnadlestaniecrncnstsGnarantaccantlirdteakeetaediininiaeates 115 4 8 2 DMM OMSL NS casa atari E EAA AE labia T 116 4 8 3 This is how you remove a Motor Module ccccesecseceeeseeecceecsecsecseeaeceesaeeecsassessecsesaeeaeeeesaees 117 ABA This is how you install a Motor Module is sisieissncivasridueissvaniutenasadbuadaadaedansinidiienndtivsnxdbennicnagisae 119 4 9 Smart Line Modules eaaa aa cen E E NE EE E EEE 121 4 9 1 SLM lt 16 kW statusidis play Sieisen eni oiiaii an ai ai 121 4 9 2 SLM lt 16 KW COMMS CMON Sete siestnseissnadsixsssaucetossuetadesasioesieonscnasasislsiansponeestiaanstanteatadiacheneeticassee 122 4 9 3 SLM 16 kW and higher status displays cccccecceecsecseeseeeceeeecseesecaecaeceesaececsaesesaeeaesaeeateatees 123 4 9 4 SLM 16 kW and higher GORE GUO S scx satiny cascades sintsdins escavaiencsi ndivndiesaulstaecunturoainiasdans 124 4 9 5 This is how you remove an SLM a tat Soca ect ecndaca Sedu cede anced nasi Rabcnente dese cedeleusc eden nennen 125 4 9 6 This is how you install an LN actin tessa ccd cau shale hatohera neste tesciaieastnsunla sa labaluaeaNtadbctaSudbeiatle 127 4 10 Active Li
52. d in series startup 6 Press OK eos OK The Select Startup Archive window opens and the data tree is displayed 30 Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO Service cases software 3 2 Series commissioning 7 Select the required commissioning archive ARD Example Archives gt Manufacturer Read in data class archive TA_TEST ard 8 Press OK a A window with the data of the selected archive is displayed 9 Data is read in when pressing OK 10 In the case of errors or problems import can be terminated by pressing the Cancel softkey Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BAO 31 Service cases software 3 3 Software backup 3 3 Software backup 3 3 1 This is how you generate a software backup Overview With Create software backup a function is provided to generate a backup of the system software including all of the user data saved on the system card This backup represents the Backup of the machine Note Memory size At least 1 GB The backup does not contain a license key in order to guarantee use for series production To generate the backup of the system software clone a storage medium CompactFlash Card or USB FlashDrive with a minimum memory size of 1 GB is required Other data carriers are not permissible Generating the system software backup clone Procedure 1 Switch the control on 2 Perform
53. de the permissible tolerance range Green OFF The component is ready for operation and cyclic DRIVE CLIQ communication is taking place Orange The component is ready for operation and cyclic DRIVE CLIQ communication is taking place The DC link voltage is present Red The component is ready for operation and cyclic DRIVE Check the line supply CLIQ communication is taking place voltage The DC link voltage is too high Orange Orange DRIVE CLiQ communication is being established Red This component has at least one fault Remove the fault and Note acknowledge The LED is controlled irrespective of the corresponding messages being reconfigured Green red Firmware is being downloaded 0 5 Hz Green red Firmware download has been completed Wait for Carry out a POWER ON 2 Hz POWER ON Green orange Component recognition via LED is activated p0124 or red orange Note Both options depend on the LED status when module recognition is activated via p0124 1 N DANGER Irrespective of the state of LED DC Link a hazardous DC link voltage can always be present The warning information on the components must be carefully observed Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 115 Service cases hardware 4 8 Double Motor Modules 4 8 2 DMM connections Connections X21 X22 Terminals X
54. ductive and capacitive interference does not in any way impair the automation and safety functions N DANGER Repairs to devices that have been supplied by our company may only be carried out by SIEMENS customer service or by repair centers authorized by SIEMENS When replacing parts or components only use those parts that are included in the spare parts list EMERGENCY STOP EMERGENCY OFF devices according to EN 60204 1 VDE 0113 Part 1 must remain active in all modes of the automation equipment Resetting the EMERGENCY STOP EMERGENCY OFF device must not cause an uncontrolled or undefined restart Anywhere in the automation equipment where faults might cause physical injury or major material damage in other words where faults could be dangerous additional external precautions must be taken or facilities must be provided that guarantee or enforce a safe operational state even when there is a fault e g using an independent limit value switch mechanical locking mechanisms EMERGENCY STOP EMERGENCY OFF devices N DANGER External power supply units for supplying components of the drive control must have safety isolation from circuits with dangerous voltages DVC A according to EN 61800 5 1 SELV PELV In addition only power units with control circuits that have safety isolation from circuits with dangerous voltages may be connected Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO S
55. e 36 Service Manual 03 2010 6FC5397 5DP20 0BA0 Service cases software 3 3 Software backup 4 The Startup menu is displayed Startup menu Reload saved user data Install software update backup Create software backup NCK default data Drive default data PLC default data HMI default data Factory settings Delete OEM data PLC Stop Normal system startup 5 Using the cursor keys select the menu item Install software update backup 6 Press the lt INPUT gt key to confirm your selection 7 Insert the storage medium with the backup in the slot and confirm with Yes by using the cursor keys to make the selection Setup menu Normal startup Reload saved user data Install software update Do you want to install the software update Then insert your CF card or USB Stick and press yes Les Factory settings Delete OEM data PLC Stop Installs a software update backup image Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BAO 37 Service cases software 3 3 Software backup 8 Select the valid backup using the cursor keys Install software update backup Software images 828d_image tgz oO Press SELECT to refresh list of software images Press INPUT to continue with selected software image Installs a software update backup image 9 Press the lt Input gt key to confirm your selection
56. e Customer Login License Keys Multiple licenses may be assigned at the same time Sry Lierse key To begin the assignment process select from one of the following choices i 3 Manage license pool Usage Guide a TO Demonstration rar Direct Access This access makes it possible for you to assign all to license which you have got with a delivery Direct login barcode scanner This entrance is optimized tor the operation of a bar code scanner You hereby can assign all Lo Certificates of License included with a bar code scanner aaa Customer Login if you have a personal entrance this be of use login for customers to assign all license which was delivered to you till now Siemens AG 2008 Automation amp Drives 2 3 2 22 04 2008 Webmaster Corporate Information Privacy Policy Terms of Use 2 Press the menu item Display license key 3 A window with the license key opens Show License Key Pressing the button will show you the current License Key At least one license must have been assigned yet Please select Please enter a search string Get License Key up Hardware and Software 58 Service Manual 03 2010 6 C5397 5DP20 0BAO Service cases software 3 6 Licensing 4 In the menu select Hardware serial number and enter the serial number of the system CompactFlash Card Show License Key Pressing the button will show you the current License Key At least one licens
57. e CompactFlash Card or a USB FlashDrive with the image into the slot on the front panel of the control Install software update backup Software images 828d_image tgz oO Press SELECT to refresh list of software images 2 Press INPUT to continue with selected software image Installs a software update backup image 5 Confirm the selection with the lt INPUT gt key 6 The following message briefly appears Starting software update Then the screen goes dark for several seconds Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BAO 49 Service cases software 3 5 Mini boot system on the CompactFlash Card 7 Ifa valid image has been found the following message is output Do not operate or switch off until software update is finished Restoring complete Switch off and remove data medium 9 Switch the control off 10 Switch the control system back on again The control boots normally Note If the system was booted using a mini boot system there is no valid license key on the system CompactFlash Card This must be transferred again Result The following cases are possible e The control boots and is ready for operation if when generating the system image the internal data backup and also a series commissioning file were generated e Ifa valid image is not found the update is interrupted with the following message Image file is corrupt In this case switch
58. e module state LED state Description cause Remedy Ready H200 DC Link H201 OFF OFF Electronics power supply is missing or outside permissible tolerance range Green OFF The component is ready and cyclic DRIVE CLiQ communication is taking place Orange The component is ready and cyclic DRIVE CLiQ communication is taking place The DC link voltage is present Red The component is ready and cyclic DRIVE CLiQ Check the line supply communication is taking place voltage The DC link voltage is too high Orange Orange DRIVE CLiQ communication is being established Red This component has at least one fault Remove the fault and Note The LED is controlled irrespective of the corresponding messages being reconfigured acknowledge Green red 0 5 Hz Firmware is being downloaded Green red 2 Hz Firmware download has been completed Wait for POWER ON Carry out a POWER ON Green orange or Red orange Component recognition via LED is activated p0124 Note Both options depend on the LED status when module recognition is activated via p0124 1 N DANGER DC link voltage Irrespective of the state of LED DC Link a hazardous DC link voltage can always be present The warning information on the components must be carefully observed Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 123 Service cases hardware
59. e must have been assigned yet Please select Please enter a search string 20060613009E2DC6 Get License Key up 5 Press the Display license key softkey 6 The actual license key is displayed as follows Show License Key Pressing the button will show you the current License Key At least one license must have been assigned yet Hardware serial number gt 2006061 3009E2DCE Get License Key Current License Key VT5X SATL AF Additionally you can get a License Report by email summarizing all assigned licenses Email address Request for License Report The license key can be saved in a file Save license key as textfile for usage with the SINUMERIK Controller Note The Save as Dialog is shown after doing a right click on the above hyperlinks up Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO 59 Service cases software 3 7 Enter the final end user data EUNA 3 7 Enter the final end user data EUNA Precondition At least access level 3 must be set to change the end user final destination data EUNA Repair and Service Contract RSC SINUMERIK offers an electronic logbook in which all of the activities relating to the Repair and Service Contract RSC are saved After the service call has been completed the control data are checked and are transferred to the EUNA database for update 3 7 1 This is how you generate the machine logbook
60. eady been done label all connectors cables that lead to the module now Only then can it be ensured that the cables are not interchanged 4 Withdraw the enable terminals X21 5 Withdraw the connected DRIVE CLiQ cables X200 X202 6 Withdraw the line supply connection X1 Z N DANGER Risk of electric shock A hazardous voltage is present for up to 5 minutes after the power supply has been switched off The protective cover must not be opened until this time has elapsed The warning information on the components must be carefully observed 7 Open the protective cover of the DC link voltage using a suitable tool e g a screwdriver 8 Withdraw the 24 V terminal adapter Service Manual 03 2010 6FC5397 5DP20 0BA0 125 Service cases hardware 4 9 Smart Line Modules 9 Using a multimeter set the measuring range to 1000 V DC at the points DCP DCN check that the DC link voltage is in a no voltage condition Only continue with the work when it has been absolutely ensured that no voltage is present no voltage condition has been established 10 Withdraw the red 24 V jumper plug 11 Release the Torx screws of the DC link Torx T20 12 Open the DC link busbars of the two modules 13 Release the screws that are used to retain the module to the mounting plate 14 Remove the protective conductor connection of the module 15 Remove the module from the control cabinet Hardware and Software 12
61. ect then it must be replaced by an identical module 136 Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO Service cases hardware 4 11 SMC20 SMC30 Preconditions e The module is defective and must be replaced e The control cabinet is in a no voltage condition all of the connectors and cables are labeled Removing 2 Swivel module to the front i Mounting slide ith 1 Press lug downwards Figure 4 26 SMC20 removal NOTICE Electro static discharge ESD Before you touch the module discharge yourself at the cabinet or at the ground terminal Procedure 1 Withdraw the electronics power supply connector X524 and label 2 Unscrew the encoder connecting cable at X520 or X521 X531 if required also the shield connection 3 Withdraw the DRIVE CLiQ cable X500 and write the slot designation on the cable 4 Release the protective conductor connection and write the position designation on the cable 5 Push the lug downwards 6 Swivel the module to the front Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO 137 Service cases hardware 4 11 SMC20 SMC30 CAUTION The 50 mm clearances above and below the components must be observed 4 11 4 This is how you install an SMC20 Installing Procedure 1 Place the components on the mounting rail 2 Then swivel the components on the mounting rail so that the mo
62. eeesrrnsserneseerenarrnunetnnnnnrnnnentnnnantnnaneannnne of 3 7 Enter the final end user data EUNA c c ceeesceeeeeeeeeeeeeeaeeceeeeecaeeesaaeeeeeeeseeeeseaeeeseaeeseeeeenees 60 3 7 1 This is how you generate the machine lOQDOOK cceecceeeeeeeeeeeeeeeeeeeeeaeeeeeeaeeeeeeaeeeeeenaeeeeseaas 60 3 7 2 This is how you make a new entry in the lOQDOOK 0 0 eee eeeeeeeeeeeneeeeeeeaeeeeeeaeeeeeeaeeeeeeaeeeeneaas 62 3 7 3 This is how you save the machine identity 0 0 ec eeeeeeeeeeeeeeeeeaeeeeeeeaeeeeeeaaeeeeeeaeeeeeenaeeeeeeaas 64 3 7 4 This is how you send the end user final destination data ie eeeeeeeeeeeeeeeeneeeeeeneeeeeenaeeeeeeaas 66 4 Serice cases NAAWale issnin eree aus ear aaa a a a E ave ee ab neti EE aa teins 69 4 1 PPU260XIPPU28 Kiinaan cx inscgsccbagecdeeuaccqenibvaed efuancaetantetadaduas paudzinsaediieanecenentepedvadangeitestins 71 4 1 1 Status displays at the PPU sesira estat eaddeedl epeatencpeedadel apsath eepedatteapeael iieedencenedevetieee a 4 1 2 This is how you remove the PP ii c cccesccccstiecccesneseccsaneeeeessnaeeessanseeecvinadecesanavecevsnteeessanieesevinse 03 4 1 3 This is how you instal the PPU sinisiraan eerie de SR A aR AAA 14 4 2 Replacing the system CompactFlash Card sssseesssneesernensnnnnsnennaansnnannennannannanennnaatannaaeennnananaa 76 Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 7 Table of contents 4 2 1 This is how you remove the system Compac
63. efore you touch the module discharge yourself at the cabinet or at the ground terminal Procedure 1 Switch off the control Completely switch off the system Check that the system is in a no voltage condition and is locked out so that it cannot be switched on again without the appropriate authorization 2 Access the control cabinet where the infeed module is located 3 If it has not already been done label all connectors and cables that lead to the module now Only then can it be ensured that the cables are not interchanged 4 Withdraw the enable terminals X21 and X22 if available 5 Withdraw the connected DRIVE CLiQ cables X200 X202 6 Release the fixing screw Torx and remove the motor connection X1 and X2 if available Z N DANGER Risk of electric shock A hazardous voltage is present for up to 5 minutes after the power supply has been switched off The protective cover must not be opened until this time has elapsed The warning information on the components must be carefully observed 7 Open the protective cover of the DC link voltage of the defective module as well as the adjacent module if available using a suitable tool e g a screwdriver 8 Withdraw the 24 V terminal adapter Service Manual 03 2010 6FC5397 5DP20 0BA0 111 Service cases hardware 4 7 Single Motor Modules 9 Using a multimeter set the measuring range to 1000 V DC at the points DCP DCN check tha
64. ening lug Opening lug Figure 4 4 SINAUT modem 1 Using a suitable object press one of the two opening lugs carefully so that the fastener opens Hardware and Software 82 Service Manual 03 2010 6FC5397 5DP20 0BA0 Service cases hardware 4 3 SINAUT modem 2 Remove the rear section of the housing 3 The SIM card holder can be seen on the printed circuit board Here LE IEAI SIM card holder Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BAO 83 Service cases hardware 4 3 SINAUT modem Inserting the SIM card NOTICE When handling SIM cards carefully observe its safety instructions When changing the SIM card do not forget to change the PIN in your control If you are using a lot of SIM cards it may make sense to set all SIM cards e g with one cellular phone to the same PIN Proceed as follows to insert the SIM card 1 Using your fingernail or a suitable object slide the upper section of the SIM card holder approximately 2 mm in the direction of the arrow to the left so that the upper section can be flipped up BISTAR b UBL tlm pane oan imn ea 2 Flip up the upper section of the SIM card holder so that you can insert the SIM card into this section k dede bd rad FEE bbe Hardware and Software 84 Service Manual 03 2010 6FC5397 5DP20 0BAO Service cases hardware 4 3 SINAUT modem The slot for the SIM card in the upper section
65. ertain data e g INDIVIDUAL are to be backed up 6 Press the Generate archive softkey archive The Generate Archive Select Archive window opens 7 Select the storage location of the archive Archives Internal memory on the CompactFlash Card system 8 Select a directory Example Archives gt Manufacturer OR 9 Press the New directory softkey to generate a new directory New directory The New Directory window opens 10 Enter the required name and confirm with OK a OK The directory is created subordinate to the selected folder 11 Press the OK softkey E G OK The Generate Archive Name window opens 12 Enter the required name and confirm with OK vo OK A file with the ARD format type is saved in the selected directory Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO 29 Service cases software 3 2 Series commissioning 3 2 4 CompactFlash Card Reading in an archive from the system CompactFlash Card This is how you import a series commissioning archive from the system A description is provided here how you read in a series commissioning archive in order to be able to restore the previous state of the machine Procedure 1 Select the Start up operating area AS Start up 2 Press the menu forward key 3 Press the Series startup softkey Series al start u 4 Press OK s OK The Series Start up window opens 5 Activate Rea
66. f a module has a hardware defect then it must be replaced by an identical module Preconditions e The module is defective and must be replaced e The control cabinet is in a no voltage condition all of the connectors and cables are labeled NOTICE Electro static discharge ESD Before you touch the module discharge yourself at the cabinet or at the ground terminal Procedure 1 Switch off the control Completely switch off the system Check that the system is in a no voltage condition and is locked out so that it cannot be switched on again without the appropriate authorization 2 Access the control cabinet where the infeed module is located 3 If it has not already been done label all connectors cables that lead to the module now Only then can it be ensured that the cables are not interchanged 4 Withdraw the enable terminals X21 5 Withdraw the connected DRIVE CLiQ cables X200 X202 6 Withdraw the line supply connection X1 Z N DANGER Risk of electric shock A hazardous voltage is present for up to 5 minutes after the power supply has been switched off The protective cover must not be opened until this time has elapsed The warning information on the components must be carefully observed 7 Open the protective cover of the DC link voltage using a suitable tool e g a screwdriver 8 Withdraw the 24 V terminal adapter Service Manual 03 2010 6FC5397 5DP20 0BA0 131 Servi
67. f off off Power On voltage is stable on off off off off off Boot software runs and loads the system on on on on on off software System software runs on off off off off off System software runs no communication to on off off off off off the controller System software runs communication to the on on off off off off controller STOP state System software runs communication to the on Flashes at off off off off controller RUN state 0 5 Hz Overtemperature alarm on 98 Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0OBAO Service cases hardware 4 5 I O modules LEDs at port 1 and port 2 There are 2 LEDs at port 1 and port 2 for diagnostics of the PLC I O interfaces based on PROFINET LED for communication at the RJ45 connector Name Color State Meaning Link Green ON 100 MBit link available OFF Missing or faulty link Activity Yellow ON Sending or receiving OFF No activity 4 5 2 This is how you remove the PP 72 48D PN Overview The activities necessary to replace the PP72 48D PN I O module are described in the following If the PP 72 48D PN has a hardware defect then this must be replaced by an identical module Preconditions e The I O module is defective and must be replaced e The control cabinet is in a no voltage condition all of the connectors and cables are labeled Hardware and Software Service Manual 03 2010 6 C5397
68. ffered memory is stored in the permanent memory Backup of selected data e g only machine data and no workpiece programs is not possible Data can be backed up without a password i e always Note Data backup After making important changes to the data immediately backup data e g after the 1st commissioning and the 2nd commissioning Preconditions e The control system has powered up e The power supply voltage is guaranteed during the data backup Proceed as follows to generate the internal data backup 1 Press the lt MENU SELECT gt key MENU SELECT 2 Select the Start up operating area AS Start up 3 Press the Save data softkey Save data Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 Service cases software 3 1 Backing up user data 4 This is followed by the Query to backup data Machine Axis Motor Index Name Type No Identifier Type Channel 1 MXI Linear CHAN1 2 M2 Linear CHAN1 3 MSP1 CHAN1 4 MSP2 CHAN1 5 MB1 CHAN1 6 MSP3 CHAN1 7 MM CHAN1 Current access level Manufacturer Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BAO 19 Service cases software 3 1 Backing up user data 5 Press the OK softkey to backup the data eat OK A progress indicator indicate the status of the data backup After the data backup has been successfully completed the following message is output 0
69. for the operation of a bar code scanner You hereby can assign all LF Certificates of License included with a bar code scanner ear PE Customer Login It you have a personal entrance this be of use 7 login for customers to assign all license which was delivered to you I till now up Siemens AG 2008 Automation amp Drives 2 3 2 22 04 2008 Webmaster Corporate Information Privacy Policy Terms of Use 7 After completing the assignment process enter the license key displayed in the Web License Manager into the Licensing dialog box in SINUMERIK Operate Note License key via e mail If you have an e mail address you have the option checkbox of receiving the license key by e mail Entering the license key The newly purchased license key is entered into the control Procedure 1 Select the Start up operating area AS Start up 2 Press the menu forward key T Hardware and Software 56 Service Manual 03 2010 6FC5397 5DP20 0BA0 Service cases software 3 6 Licensing 3 Press the Licenses softkey L Lic enses 4 Press the Overview softkey Overview If you receive the license key via the Web License Manager enter the license key manually in the field You can enter a new license key here 5 Press the lt INPUT gt key If the license key is valid the message License key set is displayed 3 6 5 This is how you display the actua
70. ftware Data backup If a system update is necessary then the system data must be backed up so that no data is lost in the case of a problem In this case we recommend to perform two types of data backup 1 Generate an image of the system CompactFlash Card clone see also This is how you generate a software backup Page 32 A backup is generated just in case an error occurs during the update This means that it is then possible to restore the old system 2 Generate an archive for series commissioning see This is how you generate a series commissioning archive on an external data carrier Page 23 in order to restore the machine specific data The control is booted using a tgz file on the storage medium CompactFlash Card or USB FlashDrive in the slot at the front panel of the control Note Backup and archive the data of the control system to an external data carrier before booting Observe the information in the update instructions Updating the control Preconditions e The control system is switched off e The image for the update is saved on the CompactFlash card e The CompactFlash card is inserted in the slot on the front panel of the control Procedure 1 Switch on the control again as the image can only be generated when booting After the control has been switched on the following display appears Press SELECT key to enter setup menu Hardware and Software 40 Service Manual 03 2010
71. h a green and a yellow LED As a consequence the following connection information of the PLC I O interface is displayed based on PROFINET Name Color State Meaning Link Green ON 100 MBit link available OFF Missing or faulty link Activity Yellow ON Sending or receiving OFF No activity Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 Service cases hardware 4 1 PPU26x PPU28x There are 2 additional LEDs FAULT and SYNC next to port 1 which apply to both ports Name Color State Meaning FAULT Red OFF The data exchange to all configured IO devices runs without errors Is lit Bus fault e No physical connection to a subnet switch e Incorrect transmission rate e Full duplex transmission is not activated Flashing e Failure of a connected I O device 2 Hz e Atleast one of the assigned IO devices cannot be addressed e Incorrect or no configuration SYNC Green OFF Task system of the SINUMERIK 828D is not synchronized to the send clock of the PLC I O interface based on PROFINET IO An internal substitute clock of the same size as the send clock will be generated Is lit Task system of the SINUMERIK 828D has synchronized to the clock of the PLC I O interface based on PROFINET IO data is being exchanged Flashing Task system of the SINUMERIK 828D has synchronized to the 0 5 Hz clock of the PLC I O interface based on PROFINET IO data is being cyclically exc
72. h options depend on the LED status when module recognition is activated via p0124 1 N DANGER Irrespective of the state of LED DC Link a hazardous DC link voltage can always be present The warning information on the components must be carefully observed Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 109 Service cases hardware 4 7 Single Motor Modules 4 7 2 SMM connections Connections X21 Terminals X200 X203 Unlockin Electronics power a supply Protective cove 24 V jumper plug E ee under the protective cover S A DC link 1 0 5 x 3 5 a lin busbars Protective cover ae naa LEDs Type plate Protective conductor X1 connection Motor connection M5 3 Nm Figure 4 20 Single Motor Module SMM Hardware and Software 110 Service Manual 03 2010 6FC5397 5DP20 0BAO Service cases hardware 4 7 3 Overview Removing Hardware and Software 4 7 Single Motor Modules This is how you remove a Motor Module The activities required when replacing a Motor Module are subsequently described If a Motor Module has a hardware defect then it must be replaced by an identical module Preconditions e The module is defective and must be replaced e The control cabinet is in a no voltage condition all of the connectors and cables are labeled NOTICE Electro static discharge ESD B
73. h positions 9 and 10 guarantee the PROFINET functionality of the module and must always be switched on NOTICE A new address only becomes effective after voltage OFF gt ON Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 105 Service cases hardware 4 6 Expansion module NX10 4 6 Expansion module NX10 4 6 1 Status displays on the NX10 LEDs for status display The following LEDs on the NX10 provide information about the module state LED Color State Description RDY H1 OFF Electronics power supply outside the permissible tolerance range Green Continuous light Component is ready Flashing light 2 Hz Writing to CompactFlash Card Red Continuous light There is at least one fault e g RESET watchdog monitoring basic system fault NX10 is booting Flashing light 0 5 Hz Error when booting e g the firmware cannot be loaded into the RAM Yellow Continuous light Firmware is being loaded into the RAM Flashing light 0 5 Hz Firmware cannot be loaded into the RAM Flashing light 2 Hz Firmware CRC error DP1 OFF Electronics power supply outside the permissible tolerance range oo NX10 is not ready Green Continuous light CU_LINK is ready for communication and cyclic communication is running Flashing light 0 5 Hz CU_LINK is ready for communication and no cyclic communication is running Red Continuous light At least one CU_LINK fault is present
74. hanged 4 1 2 This is how you remove the PPU Removing The following description refers to both versions vertical horizontal Precondition For this description it is assumed that the PPU has been completely connected Procedure 1 Switch off the control Completely switch off the system Check that the system is in a no voltage condition and is locked out so that it cannot be switched on again without the appropriate authorization 2 Access the control panel control cabinet where the PPU is installed 3 Use a multimeter to check that the system really is in a no voltage condition isolated from the supply If it has not already been done label all connectors that lead to the module now Only then can it be ensured that the cables are not interchanged Withdraw the power supply X1 Withdraw the digital input output terminals X122 X132 X142 a da Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO 73 Service cases hardware 4 1 PPU26x PPU28x 4 1 3 Installing 74 8 Withdraw the handwheel terminal X142 9 Withdraw the RS232 cable X140 10 Withdraw the USB cable X135 11 Withdraw the connected DRIVE CLiQ cable X100 X102 12 Withdraw the connected Ethernet cable X130 13 Withdraw the connected PN interfaces PN1 PN2 14 Remove the ground connection by releasing the grounding screw 15 If required release the strain relief 16 Release the PPU from the oper
75. her all of the cables have been re connected 13 Close the cabinet and switch on the system again CAUTION Ensure that all of the connectors and screws are correctly tightened and latched or inserted Z N WARNING The components must only be operated when the protective cover of the DC link is closed Damaged components must not be used Hardware and Software 128 Service Manual 03 2010 6FC5397 5DP20 0BA0 Service cases hardware 4 10 Active Line Modules 4 10 Active Line Modules 4 10 1 ALM status displays Status displays The Active Line Module ALM has the following status displays which provide information about the module status LED state Description cause Remedy Ready H200 DC Link H201 OFF OFF Electronics power supply is missing or outside permissible tolerance range Green OFF The component is ready for operation and cyclic DRIVE CLIQ communication is taking place Orange The component is ready for operation and cyclic DRIVE CLIQ communication is taking place The DC link voltage is present Red The component is ready for operation and cyclic DRIVE Check the line supply CLIQ communication is taking place voltage The DC link voltage is too high Orange Orange DRIVE CLiQ communication is being established Red This component has at least one fault Remove the fault and Note acknowledge The LED is controlled irrespective of the
76. ions Modules with their own power supply units e g batteries are an exception These may not be placed on conductive surfaces as this might result in short circuits and thus destroy the component on the module e Never place modules in the vicinity of display units monitors or television sets minimum distance to the screen gt 10 cm e Do not bring ESD sensitive modules into contact with chargeable and highly insulating materials such as plastic insulating table tops or clothing made of synthetic materials e Measurements may only be carried out on modules under the following conditions The measuring device is grounded via a protective conductor When floating measuring equipment is used the probe is briefly discharged before making measurements e g a bare metal control housing is touched 154 Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO Appendix B 1 List of abbreviations Abbreviation Meaning Explanation ALM Active Line Module ASCII American Standard Code for Information American coding standard for the exchange of Interchange information AUTO Automatic operating mode BAG Mode group BERO Proximity limit switch with feedback oscillator BICO Binector Connector Interconnection technology for the drive CEC Cross Error Compensation CNC Computerized Numerica
77. ish to create a CF card image or you would like to write a CF card image to m Please select memory medium Em Cancel Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO Service cases software 3 5 Mini boot system on the CompactFlash Card 8 Confirm the selection of the target drive with OK By pressing the Write button the image is transferred to the target drive Create SINUMERIK 828D boot system 2 x Please select the memory medium to which the SINUMERIK boot system image is to be written for an 828D Memory medium CF card F Write Cancel NOTICE While the data is being transferred do not switch off the PC and do not remove the CompactFlash Card Data transfer is displayed using a progress bar Please select the memory medium to which the SINUMERIK boot system image is to be written for an 828D Memory medium CF card a Cancel The following message is output if data transfer was successfully completed RCS Commander xj e al Writing Boot system image to medium CF card successful 10 In order to ensure that there are no read and write access operations to the CompactFlash Card when you remove the CompactFlash Card from the interchangeable drive select the Windows function Safely remove hardware Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BAO 47 Service cases software 3 5 Mini boo
78. issing or outside permissible tolerance range Yellow Continuous DC link voltage in the permissible tolerance light range Red Continuous DC link voltage outside the permissible Check the line supply voltage light tolerance range Line supply fault N DANGER DC link voltage Irrespective of the state of LED DC Link a hazardous DC link voltage can always be present It must be checked that it really is in a no voltage condition The warning information on the components must be carefully observed Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 121 Service cases hardware 4 9 Smart Line Modules 4 9 2 Connections 122 SLM lt 16 kW connections X21 X22 Terminals X24 24 V terminal adapter Unlocking Protective cover G seed a Protective A cover 2 Weis ARN QD mat LEDs Protective conductor connection M5 3Nm Figure 4 22 SLM connections om Eas Electronics power supply DC link busbars x1 Line connection Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BAO Service cases hardware 4 9 Smart Line Modules 4 9 3 SLM 16 kW and higher status displays Status displays The Smart Line Modules 2 16 kW have the following status displays which provide information about th
79. l Control Computerized numerical control DB Data Block in the PLC DBB Data Block Byte in the PLC DBW Data Block Word in the PLC DBX Data Block Bit in the PLC DDE Dynamic Data Exchange Dynamic Data Exchange DIN Deutsche Industrie Norm DO Drive object Drive Object DRAM Dynamic Random Access Memory Dynamic memory block DRF Differential Resolver Function Differential resolver function handwheel DRY DRY run DRY run feedrate ESR Extended Stop and Retract FIFO First In First Out Method of storing and retrieving data in a memory GUD Global User Data Global user data Hardware Hardware HD Hard Disk Hard disk HMI Human Machine Interface Controller user interface HSC High Speed Cutting IGBT Insulated Gate Bipolar Transistor IME Input Method Editor Entering Asian characters INC Increment Increment INI Initializing Data Initializing data IPO Interpolator IRT Isochronous Real Time Isochronous communication ISO International Standardization Organisation International Standards Organization JOG Jogging operating mode Jogging via the direction keys Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BAO 155 Appendix B 1 List of abbreviations Abbreviation Meaning Explanation LEC Leadscrew Error Compensation Leadscrew error compensation LED Light Emitting Diode Light emit
80. l license key Overview The following options are available to display the actual license of the control e Directly at the SINUMERIK control e Without control in the Internet You require the serial number of the system CompactFlash Card in order to display the actual key in the Internet This is displayed at the control in the Licenses dialog box or can be read from the system CompactFlash Card Displaying the actual license key at the control Proceed as follows to display the license key at the control 1 Select the Start up operating area A Start up 2 Press the menu forward key 3 Press the Licenses softkey to display the control licenses e Lic enses Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 57 Service cases software 3 6 Licensing Displaying the actual license key in the Internet In order to view the actual license key of the control using the serial number it is possible display the license key via the Internet The serial number is on the system CompactFlash Card or can be displayed at the control as described above 1 Go to the Internet page of the Web License Manager a a AO TE a SG i Home Deutsch Re Motion Control Web License Manager ee ee Welcome to the Web based software license management of SIEMENS A amp D ie Direct access bar code scanner This tool enables you to assign software licenses to a target system and to generat
81. ldwide If it was not possible to transfer the file then please contact your local Siemens officeContact http www automation siemens com partner in sales Service Manual 03 2010 6FC5397 5DP20 0BA0 67 Service cases software 3 7 Enter the final end user data EUNA 68 Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO Service cases hardware Overview The sequence in the chapter of the hardware components corresponds to the following criteria Components at the machine Components in the control cabinet Component overview Control Unit Extension Motor Modules D Line Modules Kf ae Single Motor Smart Line Modules Modules Double Motor Active Line Modules Modules Sensor Modules Additional system components DMC20 SMC20 SMC30 SME20 SME25 SAA Em Figure 4 1 Components in the control cabinet Note A special tool is supplied to unlock the DC link covers of SINAMICS components Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BAO 69 Service cases hardware Using the unlocking tool An unlocking tool is supplied with every power unit for the purpose of opening the DC link covers The diagrams below illustrate how the tool should be used Hardware and Software 70 Service Manual 03 2010 6 C5397 5DP20 0BAO Service cases hardware 4 1 PPU26x PPU28x 4 1 1 Status displays at the PPU LED status at the front 4 1 PPU26x PPU28x
82. mmander Note An online connection to the control is not required to generate the boot system 3 If you are prompted to establish the connection press Cancel Selecting connection 2 x Please select the connection which you want to establish Available connections irect Connection 192 1 Control information Control IP 192 168 215 1 Port 22 Control name not possible direct connection Remote display IP 192 168 215 1 Port 5900 E 4 In the View menu select the menu item Expert view The following additional NC commissioning menu is displayed NC commissioning Settings Help Creating the CF card image Writing image to CF card Creating SINUMERIK 828D boot system 5 Select menu item Generate 828D boot system Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 45 46 Service cases software 3 5 Mini boot system on the CompactFlash Card 6 If several versions of the toolbox are installed on the PC you obtain the following selection Selecting version r 2 x Several toolboxes of the 828D are installed on your PC Please select the relevant version here Available versions v02 05 03 00 cme 7 All of the identified interchangeable drives are displayed here in the example the CompactFlash Card is identified as drive F Selecting memory medium 2 x Please select here the memory medium from which you w
83. n iaa aiaa eaaa ai aiee aided cena dete 144 4 12 1 SME20 CONNECTIONS 0 0 0 ccc cececceceecesecssececssecssessecsaccaeesecuaccsessesusecsasseesaecsaecsecsecsascaecesssecaeceseeasenes 144 4 12 2 This is how you remove an SME20 and install it AGAIN cece ee ette eect eete eter eaeeeeeenaeeeeee 144 4123 SMEZ5 CONNECHONS i22c feccsecsis oie cs a a E aer table Ea iA a E AE AE U a den 145 4 12 4 This is how you remove an SME25 and install it again 0 aeeeeeeeeeeeeeeeeeeeeereser rss resrensseeen 146 4 13 DMC 20iseraienonnias eiia E aE TEE E A EEA TE E EE E AA 147 4 13 1 DMC20 status displays 00 cc eee ee ette etree eet e ee ee tree setae seers EE ENNE EE AANE EE nant EEEn aE Ennan nnna nnee 147 4 13 2 DMC20 CONNECTIONS ccccecccceecsseessecscsescsessecsassauseecusecsessesuaessassausecssecsecsecsascseceeessecaeceneeseenas 148 4 13 3 This is how you remove a DMC20 0 000 ec eceeeeeeeee nii ania ARAKA AAAA ARA 148 4 13 4 This is how you install A DMC20 eee eeeeeee eect ee ee eene ee ee ee ee ee eaeee eet aeeeeesaeeeeetneeeeeeneeeeee 150 5 Spare parts and accessories twscssssevcieesisasiceee colt esecenidueceulaes javdevaelediacaslveceveneteved eteessvecsacenceacecetevveeeneea ives 151 ESD QUIGCIINGS iccse srini ka eean A aiana NRA REANA Aen AAA EEA ANENE NEREA 153 A 1 RI SUPPreSSiON measures ccccceceeeeeeeeeeeeaeee cece aaia aaa a ea aSa apaa TEA aS E ANEETA 153 A 2 ESD measures isnie aa a a ae adaa eaa a ai ES
84. ndheld unit or from other command devices if available Reinsert the Ethernet cables at the X20 X21 interface port 1 port 2 Re establish the Ethernet cable strain relief Reconnect the power supply X10 Close the cabinet and switch on the system again Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO Service cases hardware 4 4 Machine control panels Switch S2 SIEMENS SSS Saul x MCP 4836 IE Dieta Outputs VOCOIA beara sus MANE ae GFCSI02 0AF22 S2 H1 H2 H3 Figure 4 12 Switch S2 Switch S2 defines the IP address of the machine control panel 1 2 3 4 5 6 7 8 9 10 Device name on on on off on off off off off off mcp pn64 For SINUMERIK 828D the IP address 192 168 214 64 must always be assigned to the MCP Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 97 Service cases hardware 4 5 I O modules 4 5 I O modules 4 5 1 Status displays PP 72 48D PN LEDs for status display The following LEDs on the I O module provide information about the module state EEFE g n A CE we of ja ri cD h we p E har a e i miin B n PETIT pi PowerOK PNSync sis PNFault DIAGI ATII LLLI DI AG2 z OVT emp Figure 4 13 Switch S1 and LEDs H1 to H6 H1 green H2 green H3 red H4 green H5 green H6 PowerOK PN Sync PN Fault Diag1 Diag2 OVTemp Power Off off off off of
85. ne Modules ssie E A AEA aa 129 4 10 1 ALM Sa eae a ance tech emcees wesc ican bane staat aen iwoni anenee naain 129 410 2 PIVOTING Svcs sacceinteseiasiiscd TAE N AE ERE 130 4 10 3 This is how you remove an ALM otal cactus sa Acca tnahasseaha tet acces pM caaeista eum du ccacavasiaach 131 4 10 4 This is how you install an PI is casa Ssactawsiaies cu ines outs cuutcaw dirtestanesauashdaleislcnemeuesaesscunt 133 4 11 SMC20 SMCS 0 nase Reet dee eee Dn ee eee ae 135 AV SMC20 status GIG Bay S siete ionsldaatavndensataaiestmsldditsscasn sales aR EE R a 135 4 11 2 SMC20 COMMONS co ance coasters unien ae eiai iaa eika Ei eiaa Aaa aiaa aE Anasa Naas auam 136 4 11 3 This is how you remove an SMC20 cccecsccesseseeseeseeseseeeecseesecsecseseesaeceesaeeecsassessesaesaesaeeeeeaees 136 4 11 4 This is how you install an SMC 20 scocccanciszisasnctocssadcncsiaanddedatatanastaasdscissannsatacandelsoaan cd tenruscueate 138 Hardware and Software 8 Service Manual 03 2010 6FC5397 5DP20 0BA0 Table of contents 4 115 SMC30 status displays tic 2sit cnniie deed etlidee dns enti EE NEEE T indeed einer 139 4 11 60 SMCSO COMMECHONS we idecissceec le ieecscdeheess alana diseaaiees Aia a EE AE aa NS ER 140 4 11 7 This is how you remove an SMC30 ssiri cece entree ee AN aA ANANA KAANAA 140 4 11 8 This is how you install an SMC30 0 0 0 eee eee cence ee eete ee ee etne ee ee tans ee ee eae sees taeeeeesaeeeeesnaeeeeesnaeeeeee 142 4 12 SME20 SME25 siriasi iiin
86. ng 150 This is how you install a DMC20 Procedure NO oO Ff Place the components on the mounting rail Then swivel the components on the mounting rail so that the mounting catches click into place at the rear Slide the components along the mounting rail to either the left or right up to their final position Screw on the protective conductor connection Screw on the encoder connecting cable to X520 Insert the DRIVE CLiQ cable at X500 X505 Insert connector X524 for the electronics power supply CAUTION The 50 mm clearances above and below the components must be observed Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO Spare parts and accessories Order data for accessories The following accessories are available Component Order No Description CompactFlash Card empty 1 GB 6FC5313 5AG00 0AA0 for SIMOTION SINUMERIK USB FlashDrive 2 GB 6ES7648 0DC40 0AA0 USB2 0 bootable See also Spares on web https b2b extern automation siemens com spares_on_web Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BAO 151 Spare parts and accessories Hardware and Software 152 Service Manual 03 2010 6 C5397 5DP20 0BAO ESD guidelines A A 1 RI suppression measures Shielded signal cables To ensure safe interference free system operation it is essential to use the cables specified in the individual diag
87. ng and FAQs Information on our range of training courses and FAQs frequently asked questions is available via the page navigation This document addresses maintenance and service personnel Based on the Service Manual the target group can correctly and safely perform service and maintenance work Utilization phase Maintenance and service phase This documentation only describes the functionality of the standard version Extensions or changes made by the machine manufacturer are documented by the machine manufacturer Other functions not described in this documentation might be executable in the control However no claim can be made regarding the availability of these functions when the equipment is first supplied or in the event of servicing Service Manual 03 2010 6FC5397 5DP20 0BAO Preface Further for the sake of simplicity this documentation does not contain all detailed information about all types of the product and cannot cover every conceivable case of installation operation or maintenance Questions about this documentation If you have any queries suggestions corrections in relation to this documentation please send a fax or e mail to the following address Fax 49 9131 98 2176 A fax form is available at the end of this document E mail mailto docu motioncontrol siemens com SINUMERIK Internet address http www siemens com sinumerik Service amp Support If you have any tech
88. nical questions please contact our hotline Phone Europe Africa 49 180 5050 222 Fax 49 180 5050 223 0 14 min from the German fixed line network cell phone charges may vary Internet http Awww siemens com automation support request Phone Americas 1 423 262 2522 Fax 1 423 262 2200 E mail mailto techsupport sea siemens com Phone Asia Pacific 86 1064 75 75 75 Fax 86 1064 74 74 74 E mail mailto techsupport asia siemens com Note Country specific telephone numbers for technical support are provided on the Internet http www siemens com automation partner Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO Preface EC Declaration of Conformity The EC Declaration of Conformity for the EMC Directive can be found on the Internet http support automation siemens com under the Product Order No 15257461 or at the relevant branch office of the DT MC Division of Siemens AG CompactFlash cards for users Hardware and Software The SINUMERIK CNC supports the file systems FAT16 and FAT32 for CompactFlash cards You may need to format the memory card if you want to use a memory card from another device or if you want to ensure the compatibility of the memory card with the SINUMERIK However formatting the memory card will permanently delete all data on it Do not remove the memory ca
89. o allow a correct assignment and further handling of the uploaded xml configuration files we need your eMail address When the checkbox eMail status notification is enabled you will receive an eMail to the entered address General contact information Language selection Y eMail address enable eMail status notification Hardware and Software 66 Service Manual 03 2010 6FC5397 5DP20 0BA0 Service cases software 4 3 7 Enter the tinal end user data EUNA In the following dialog box select the configuration files 2 Selection of xml configuration files Please select the xml configuration files which you would like to upload to the EUNA server XML Upload Assigned files isplays all assigned files T File name File size User Upload Upload date AIL Z AIBICIDIEIFIGIHIIIJIKILIMIN OJP Q Hits 1 0 0 Hardware and Software CoN O O 9 g back next gt cancel To open a navigation window press the XML Upload softkey Select the files of the machine identity that you wish to transfer to EUNA Now confirm using the softkey Upload file After the upload other files can also be uploaded During the upload the files are checked and a log is displayed for each file that has been transferred If no other files are to be uploaded press the softkey continue gt 10 Complete the upload by pressing the Save softkey Note Contact persons wor
90. of the DC link busbars observe the correct sequence 6 Place the red jumper plug on the electronics busbar until it clicks into place Observe the sequence when tightening Torx T20 1 8 Nm 7 Place the 24 V terminal adapter on the electronics power supply busbar until it clicks into place 8 Close the protective cover of the DC link voltage Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 133 Service cases hardware 4 10 Active Line Modules 9 Reconnect the line supply connection X1 at the module 10 Insert the DRIVE CLiQ cables that were previously withdrawn into sockets X200 X202 11 Reinsert the enable terminals X21 at the module 12 Check whether all of the cables have been re connected 13 Close the cabinet and switch on the system again CAUTION Ensure that all of the connectors and screws are correctly tightened and latched or inserted Z N WARNING The components must only be operated when the protective cover of the DC link is closed Damaged components must not be used Hardware and Software 134 Service Manual 03 2010 6FC5397 5DP20 0BA0 Service cases hardware 4 11 SMC20 SMC30 4 11 SMC20 SMC30 4 11 1 SMC20 status displays Status displays The Sensor Module Cabinet Mounted SMC20 has the following status displays which provide information about the module state LED Color State Description cause Remedy RDY OF
91. off the control withdraw the data carrier and carry out the procedure again by selecting a valid file Hardware and Software 50 Service Manual 03 2010 6FC5397 5DP20 0BA0 Service cases software 3 6 Licensing 3 6 Licensing 3 6 1 Licensing after replacing the system CompactFlash Card Application The license key of the SINUMERIK 828D is linked with the system CompactFlash Card If the system CompactFlash Card is replaced for a SINUMERIK 828D the license key loses its validity and the system is only ready with some significant restrictions This situation can occur for a defective hardware of the system CompactFlash Card Validity of the license key The following data are required in order to obtain a valid license key after replacing the system CompactFlash Card The serial number of the defective and the new CompactFlash Card Note Only CompactFlash Cards can be used that were released as spare part as only these are known to the license database In order to obtain a valid license key for the new CompactFlash Card contact the SINUMERIK Hotline specifying the serial numbers of the two CompactFlash Cards The hotline will immediately provide you with a new license key 3 6 2 This is how you license a CNC option Precondition You require at least one authorization to set or reset a CNC option Access level 1 password Manufacturer Licensing CNC options If an additional CNC option is to be activated at a
92. on the module that are used to connect the digital inputs and outputs 7 Remove the strain relief of the communication cables to interfaces X2 Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 Service cases hardware 4 5 I O modules 8 Remove the communication cables from interface X2 port 1 and port 2 9 Remove the ground connection by releasing the grounding screw 10 To remove the I O module release the fixing screws 11 Note down the address set with DIP switch S1 on the defective module 4 5 6 This is how you install the PP 72 48D 2 2A PN Installing Procedure 1 Set DIP switch S1 of the new module as you previously noted down 2 Install the new I O module 3 Connect the ground connection 4 Connect the communication cables at interface X2 port 1 and port 2 5 Re establish the strain relief for the communication cables 6 Re insert the connectors of the ribbon cables X111 X222 X333 on the module that are used to connect the digital inputs and outputs N Reconnect power supply X1 8 Close the cabinet and switch on the system again DIP switch S1 Setting of switch S1 1 2 3 4 5 6 7 8 9 10 Device name on off off on off off off off pp72x48pn9 off off off on off off off off pp72x48pn8 on on on off off off off off pp72x48pn7 off on on off off off off off pp72x48pn6 on off on off off off off off pp72x48pn5 The switc
93. or The assignment of a license to a piece of hardware cannot be reversed via the Web License Manager Generating a license key Procedure 1 Select the Start up operating area AS Start up 2 Press the menu forward key 3 Press the Licenses softkey Lic enses 4 Press the Overview softkey and note down the serial number of the system CompactFlash Card Overview 5 At your PG PC establish a connection to the Web License Manager http Awww siemens com automation license Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO 55 Service cases software 3 6 Licensing 6 Log on via Direct access Follow additional instructions in the Web License Manager fo aj SIEMENS slemene com s Home Deutsch Loe tS Motion Control Web License Manager p E Welcome to the Web based software license management of SIEMENS A amp D B Direct access bar code scanner This tool enables you to assign software licenses to a target system and to generate f gt Customer Login License Keys Multiple licenses may be assigned at the same time Show License Kay To begin the assignment process select from one of the following choices Manage license pool Usage Guide Demonstration jar r Direct Access This access makes it possible for you to assign all to license which you have got with a delivery Direct login barcode scanner This entrance is optimized
94. or connections X1 and X2 if available to the module 10 Insert the DRIVE CLiQ cables that were previously withdrawn into sockets X200 X202 11 Reinsert the enable terminals X21 and X22 if available into the module 12 Check whether all of the cables have been re connected 13 Close the cabinet and switch on the system again CAUTION Ensure that all of the connectors and screws are correctly tightened and latched or inserted J N WARNING The components must only be operated when the protective cover of the DC link is closed Damaged components must not be used Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 Service cases hardware 4 9 Smart Line Modules 4 9 Smart Line Modules 4 9 1 SLM lt 16 kW status displays Status displays The 5 kW and 10 kW Smart Line Modules have the following status displays which provide information about the module state LED Color State Description cause Remedy READY OFF Electronics power supply is missing or outside permissible tolerance range Green Continuous Component is ready light Yellow Continuous Precharging not yet complete light Bypass relay has dropped out EP terminals are not supplied with 24 V DC Red Continuous Overtemperature Diagnose the fault using the light output terminals and acknowledge using the input terminal Overcurrent trip DC LINK OFF Electronics power supply is m
95. or user interfaces Menu back key Alphabetic key group Control key group Hotkey group Cursor key group Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 System description OOOOoOoLO Figure 2 2 Rear of the PPU DRIVE CLiQ X100 X102 RS232 X140 Digital inputs outputs X122 X142 Handwheels X143 Figure 2 3 ql Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 Numerical block Menu forward key 3 8 threads for additional components Protective cover for user interfaces X127 Ethernet service socket Status LEDs RDY NC CF X125 USB port Slot for CompactFlash Card with user data System versions ezxnzr88s5S x122 See x132 ATTAT 222222883883 x12 EES EELE FERE I T HANDWHEEL O OOO T2 T1 TO Measuring sockets only for service purposes Interfaces on the rear side of the PPU 2 2 System versions PLC 1 0 Interface Port 1 PLC I O Interface Port 2 Ethernet LAN X130 USB X135 Power supply 24 V DC x1 15 System description 2 2 System versions Hardware and Software 16 Service Manual 03 2010 6 C5397 5DP20 0BAO Service cases software 3 Overview The following software tools should be used for the subsequently described service activities and to backup system and user data e Toolbox CD V2 6 SINUMERIK 828D with the following contents PLC Programming Tool for In
96. ou install an SMC30 Ss l OF ALALALALALALALA A A A Rotate a screwdriver with a wide blade 5 to 8 GY mm in the slot of the mounting slide through 90 or alternatively press the lug downwards Figure 4 29 Installing SMC30 Procedure 1 Place the components on the mounting rail 2 Then swivel the components on the mounting rail so that the mounting catches click into place at the rear Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO Service cases hardware 4 11 SMC20 SMC30 3 Slide the components along the mounting rail to either the left or right up to their final position 4 Screw on the protective conductor connection 5 Screw on the encoder connecting cable to X520 or X521 X531 if required also the shield connection 6 Insert the DRIVE CLiQ cable at X500 7 Insert connector X524 for the electronics power supply CAUTION The 50 mm clearances above and below the components must be observed Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO 143 Service cases hardware 4 12 SME20 SME25 4 12 SME20 SME25 4 12 1 SME20 connections Connections Encoder syste interface 12 pole Protective ground connection M4 1 8Nm DRIVE CLiQ interface Figure 4 30 Connections SME20 4 12 2 This is how you remove an SME20 and install it again Overview The activities that must be taken into account when repl
97. placement part spare part a system CompactFlash Card is not supplied 4 2 2 This is how you insert the system CompactFlash Card Precondition The control cabinet and the PPU are in a no voltage condition or the PPU has already been removed CAUTION Electro static discharge ESD The system CompactFlash card must only be inserted or removed in a no current condition Before you touch the CompactFlash Card discharge yourself at the cabinet or at the ground terminal Hardware and Software 78 Service Manual 03 2010 6 C5397 5DP20 0OBAO Service cases hardware 4 2 Replacing the system CompactFlash Card Inserting the system CompactFlash Card Procedure 1 Release the screw M3 Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BAO 79 Service cases hardware 4 2 Replacing the system CompactFlash Card 4 Reattach the metal cover by first locating it at the rear and then tilting it into the end position Note When inserting the system CompactFlash Card carefully ensure that neither the screw nor the system CompactFlash Card falls into the PPU or the machine Hardware and Software 80 Service Manual 03 2010 6 C5397 5DP20 0BAO Service cases hardware 4 3 SINAUT modem 4 3 1 LED status displays Validity This description is valid for the GPRS GSM modem MD720 3 hardware version 3 x You can find additional information in the System Manual SINAUT MD720 3 in
98. r Notification Administration EUNA 60 ESD measures 154 EUNA a Configuration file 66 Machine identity 60 Machine logbook 60 L LED status Front of the PPU 71 MCP 310C PN 89 MCP 483C PN 93 NX10 106 Rear of the PPU 72 SINAUT MD720 3 81 License key 51 _ Control 57 Web License Manager 58 Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO Licenses Save as backup 57 Licensing a CNC option 51 Logbook entry 62 aa M Mini boot system 45 R Repair and Service Contract RSC 60 RI suppression measures 153 Rules for routing cables 153 S Shielded cables 153 SIM cardg 82 SINAUT modem 82 Switch S1 on the I O module 101 105 S2 on the MCP 310C PN 93 S2 on the MCP 483C PN 97 U Unlocking tool 70 USB FlashDrive 40 151 W Web License Manager 58 165 Index Hardware and Software 166 Service Manual 03 2010 6FC5397 5DP20 0BA0
99. r number Manufacturer s name facturer Street Post code zip code Town Country Please select E State county Contact 6 Confirm your entries by clicking on OK Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO 61 Service cases software 3 7 Enter the final end user data EUNA 3 7 2 This is how you make a new entry in the logbook Generating a new logbook entry In order to log service and diagnostic procedures at the machine make an entry in the machine logbook The activities performed are logged here after each service call To make a logbook entry proceed as follows 1 Select the Diagnostics operating area AN ALARM 2 Press the Version softkey ive Version 3 Press the Logbook softkey Logbook Hardware and Software 62 Service Manual 03 2010 6 C5397 5DP20 0BAO Service cases software 3 7 Enter the tinal end user data EUNA 4 Press the New entry softkey in order to make an entry in the logbook Neuer Eintrag Complete the fields for the new logbook entry New logbook entry Name Company department Error diagnostics measure Figure 3 5 Editing the logbook 5 Press the OK softkey to save an entry in the logbook A OK For the following activities two additional softkeys are available which generate pre configured logbook entries Startup 1 Commissioning completed complete
100. r specific inputs and outputs Handwheels are directly connected to the PPU Do not wire X60 X61 MCP 310C PN rear side G Q x10 x60 x61 s s2 x21 X20 E Figure 4 8 NOTICE Electro static discharge ESD Before you touch the machine control panel discharge yourself at the cabinet or at the ground terminal Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 91 Service cases hardware 4 4 Machine control panels Procedure 1 N OQ ON 9 Switch off the control Completely switch off the system Check that the system is in a no voltage condition and is locked out so that it cannot be switched on again without the appropriate authorization Access the operator panel or control cabinet in which the machine control panel is located Using a multimeter check the X10 power supply to ensure that the system really is in a no voltage condition If it has not already been done label all connectors that lead to the module now Only then can it be ensured that the cables are not interchanged Withdraw the power supply X10 Release the strain relief of the Ethernet cable Remove the Ethernet cables from the X20 X21 interface port 1 port 2 Release other cables e g the Emergency Stop cable or the button from the mini handheld unit or from other command devices if available Remove the gro
101. rams Both ends of the shield must always be conductively connected to the equipment housing Exception If third part devices are connected printers programming devices etc you can also use standard shielded cables which are connected at one end These external devices may not be connected to the control during normal operation However if the system cannot be operated without them then the cable shields must be connected at both ends Furthermore the external device must be connected to the control via an equipotential bonding cable Rules for routing cables In order to achieve the best possible noise immunity for the complete system control power section machine the following EMC measures must be observed e Signal cables and load cables must be routed at the greatest possible distance from one another e Only use Siemens signal cables for connecting to and from the NC or PLC e Signal cables may not be routed close to strong external magnetic fields e g motors and transformers e Pulse carrying HC HV cables must always be laid completely separate from all other cables e If signal cables cannot be laid at a sufficient distance from other cables then they must be installed in shielded cable ducts metal e The clearance interference injection area between the following lines must be kept to a minimum Signal cable and signal cable Signal lead and associated equipotential bonding lead Equipo
102. rd while it is being accessed This can lead to damage of the memory card and the SINUMERIK as well as the data on the memory card If you cannot use a memory card with the SINUMERIK it is probably because the memory card is not formatted for the control system e g Ext3 Linux file system the memory card file system is faulty or it is the wrong type of memory card Insert the memory card carefully with the correct orientation into the memory card slot take note of arrows etc This way you avoid mechanical damage to the memory card or the device Only use memory cards that have been approved by Siemens for use with SINUMERIK Even though the SINUMERIK keeps to the general industry standards for memory cards it is possible that memory cards from some manufacturers will not function perfectly in this device or are not completely compatible with it you can obtain information on compatibility from the memory card manufacturer or supplier The CompactFlash card from SanDisk CompactFlash 5000 Industrial Grade has been approved for SINUMERIK Order Number 6FC5313 5AG00 0AA0 Service Manual 03 2010 6FC5397 5DP20 0BAO 5 Preface Hardware and Software 6 Service Manual 03 2010 6 C5397 5DP20 0BAO Table of contents PROTACC sisiane tees e aana aaa e Aaaa a a TAa aAa N aa aa aaraa aa eaaa e eE Aeau a Cana Ea aa lidyimelouitecadsacer tees 3 See Ae E E E E E oct A E E E E E E A EE T 11 2 System descriptors siie ainan aan ienaa ada
103. rt Preconditions e The module is defective and must be replaced e The control cabinet is in a no voltage condition all of the connectors and cables are labeled Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BAO Service cases hardware 4 4 Machine control panels Removing j EN 7 ON E E a T em a we ee j OR Oo 0 X10 Power supply interface Ground terminal X30 Feedrate override x3 Spindle override X20 Port 1 Connection PLC I O interface based on PROFINET X21 Port 2 Connection PLC I O interface based on PROFINET Slot for Emergency Stop Mounting slots for additional command devices Customer specific inputs and outputs Cover plate Ethernet cable strain relief LEDs s2 Switch S1 Switch for SINUMERIK 828D has no function X60 Handwheel connection X61 Handwheel connection Handwheels are directly connected to the PPU Do not wire X60 X61 Figure 4 11 MCP 483C PN rear side NOTICE Electro static discharge ESD Before you touch the machine control panel discharge yourself at the cabinet or at the ground terminal Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 95 Service cases hardware 4 4 Machine control panels Procedure 1 Switch off the control Completely switch off the system Check that the system is in a no voltage
104. s and screws are correctly tightened or latched and inserted 108 Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO Service cases hardware 4 7 Single Motor Modules 4 7 Single Motor Modules 4 7 1 SMM status displays Status displays The Motor Module has the following status displays which provide information about the module state LED state Description cause Remedy Ready H200 DC Link H201 OFF OFF The electronics power supply is missing or outside the permissible tolerance range Green OFF The component is ready for operation and cyclic DRIVE CLIQ communication is taking place Orange The component is ready for operation and cyclic DRIVE CLIQ communication is taking place The DC link voltage is present Red The component is ready for operation and cyclic DRIVE Check the line supply CLIQ communication is taking place voltage The DC link voltage is too high Orange Orange DRIVE CLiQ communication is being established Red This component has at least one fault Remove the fault and Note acknowledge The LED is controlled irrespective of the corresponding messages being reconfigured Green red Firmware is being downloaded 0 5 Hz Green red Firmware download has been completed Wait for Carry out a POWER ON 2 Hz POWER ON Green orange Component recognition via LED is activated p0124 or red orange Note Bot
105. s without any additional preparation Mini boot system image 3 5 1 Precondition 44 Configuration data are supplied on the toolbox CD of the SINUMERIK 828D which include in the scope of delivery of mini boot system image Toolbox 828D 02 06 00 00 Components Programs to be installed Config Data 828D S NU M E RI K Programming Tool PLC828 25 MB S oftwa re Start up tool for drives 490 MB Description Reloadable lanquages files for 828D HMI Readme Figure 3 2 Toolbox selection This program must be installed in order that the image of the mini boot system is installed on the PC PG This is how you generate a mini boot system The default path to install the mini boot system is C Program Files Siemens Toolbox 828D V02060xx00 RecoverySys The file name of the boot system is minsys img The minsys img file is copied to an empty replacement card using the RCS commander Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO Service cases software 3 5 Mini boot system on the CompactFlash Card Precondition to write e RCS Commander has been installed e SW package Configuration data from the Toolbox has been installed e CompactFlash card is a replacement card Installing the boot system on an empty card Procedure 1 Insert the CompactFlash Card into the card reader 2 Start the RCS Commander via Start gt Programs gt RCS Co
106. ser CF Read in data class archive TA_TEST ard 8 Press OK a A query is displayed here you can see the most important data of the selected archive to be certain that it is OK 9 Data is read in when pressing OK a 10 In the case of errors or problems import can be terminated by pressing the Cancel softkey Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BAO 27 Service cases software 3 2 Series commissioning 3 2 3 This is how you generate a series commissioning archive on the system CompactFlash Card Generating an archive on the system CompactFlash Card Procedure 1 Select the Start up operating area AS Start up 2 Press the menu forward key gt 3 Press the Series startup softkey Series Hl start u 4 Activate Series startup The Create Series Startup window opens Create series start up Use Easy Archive data class archives All O Execute Control components PLE data Drive data ACX format binary O ASCII format HMI data Comment Created by Series start u Hardware and Software 28 Service Manual 03 2010 6 C5397 5DP20 0OBAO Service cases software 3 2 Series commissioning 5 Select the desired control components Note Easy Archive e Select all of the components unless it is known that individual components do not deviate from the Siemens standard e Select all data classes unless only c
107. t system on the CompactFlash Card 3 5 2 This is how you install a software backup using the mini boot system Overview If a CompactFlash Card with a mini boot system is used as system CompactFlash Card the system software or a previously generated software backup must still be transferred Note Licenses The mini boot system does not contain a license key a valid license key must be transferred to the control When replacing a system CompactFlash Card this must be requested again see also This is how you license a CNC option Page 51 All system data and user data are overwritten with the system image Updating the software After you have inserted the CompactFlash Card with the mini boot system as new system CompactFlash Card see Replacing the system CompactFlash Card Page 76 proceed as follows 1 Switch the control on When booting the following display appears Install software update backup Installs a software update backup image 2 Press the lt INPUT gt key to confirm your selection Hardware and Software 48 Service Manual 03 2010 6 C5397 5DP20 0BAO Service cases software 3 5 Mini boot system on the CompactFlash Card 3 Confirm the question with Yes Setup menu Install software update Do you want to install the software update Then insert your CF card or USB Stick and press yes a Installs a software update backup image 4 Insert th
108. t the DC link voltage is in a no voltage condition Only continue with the work when it has been absolutely ensured that no voltage is present a no voltage condition has been established 10 Withdraw the red 24 V jumper plug 11 Release the Torx screws of the DC link f if L Torx 720 K Torx T20 12 Open the DC link busbars of the two modules Hardware and Software 112 Service Manual 03 2010 6FC5397 5DP20 0BAO Service cases hardware 4 7 Single Motor Modules 13 Release the screws that are used to retain the motor module to the mounting plate 14 Remove the protective conductor connection of the Motor Module 15 Remove the Motor Module from the control cabinet 4 7 4 This is how you install a Motor Module Installing N DANGER Risk of electric shock A hazardous voltage is present for up to 5 minutes after the power supply has been switched off The protective cover must not be opened until this time has elapsed The warning information on the components must be carefully observed Procedure 1 Screw the new Motor Module to the mounting plate 2 Reconnect the protective conductor connection of the Motor Module 3 Open the protective cover of the DC link voltage using a suitable tool e g a screwdriver 4 Release the Torx screws and connect the DC link busbar L Torx T20 Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 113 Service cases hard
109. tFlash Card ecccccccceeeseneeeeeeeieeeeeteneeeeeeneeeeees 76 4 2 2 This is how you insert the system CompactFlash Card cecccecseeeceeeseeeeeeeseieeeeesnneeeeeeneeeeres 78 4 3 SINAUT MOGI eieae e e tesa iets e dd ountendvieviele eueletc ee coated 81 4 3 1 PB Ns GN A i eta ih SS a idling si Able a lid dank 87 4 3 2 This is how you insert the SIM Card eecceceeeeteeeeeeeee eter eter ee erence ee eeeeeeeaeeeeesaeeeeesiaeeeesenaeeeeee 82 4 3 3 This is how you load the factory Settings ccc eeeeeee ener eeeeeeeeeeeeeaeeeeeeaeeeeesaeeeeetaeeeesenaeeeees 88 4 4 Machine control panels cc iicucsscracdseacidesdeeancueadaacecldsasadsedarasuaycanncugehanesies saesengedane suas a a 89 4 4 1 status displays MCP 310C PN crespina sau decensstepeds saudwaessiuewiua sau decenssteneeasauaees dudes 89 4 4 2 This is how you remove the MCP 310C PN 0 ccccecsceeeeeeeeeeeeeeeeneeeeetaeeeeesaeeeeeeaeeeeetaeeeenes 90 4 4 3 This is how you install the MCP 310C PN e cc ececeeee een unaa e aa AA a N A 92 4 4 4 Status displays MCP 483C PN 0 cecececceecce cece eeeeeeeeee cece ee ee seca eaaeeeeeeeeeseceaaaeeeeeeeeeseeencieeeeeeeeeeee 93 4 4 5 This is how you remove the MCP 483C PN ccccceceeeeeeeeeeeeeeeeeseaeeeeesaeeeeesaeeeeesnaeeeeseneeeeres 94 4 4 6 This is how you install the MCP 483G PN c cc ecececeeeeeeeeeeeeneeeee niania aiaa 96 4 5 VO OCIS 55 280 ag ees eee lceses cette E Seat apcedie cians teceastes
110. tegrated PLC Commissioning software for SINAMICS S120 Recovery system e RCS Commander V2 6 SP1 Backing up log files If system problems occur then it is necessary to backup all of the existing log files in order to provide these to the hotline for diagnostics There is a special shortcut key for this function CTRL ALT D This function generates a directory on the User CF card or on the front USB If both are available then the directory is created in both storage media Example The directory name has the following structure LOG_Date_Time LOG_091102_083615 stands for a directory generated on 02 11 2009 at 8 36 15 This therefore ensures that a directory is not overwritten by pressing CTRL ALT D several times The directory contains all of the logbook and debug information available in the system Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO 17 Service cases software 3 1 Backing up user data 3 1 Backing up user data 3 1 1 This is how you backup user data Application Backing up data 18 A backup of the data in the complete memory is generated with the Save data function This data backup must be performed for every control that has been commissioned in order to be able to quickly restore the control system in the case of data loss If the Create software backup function is used then it is essential to backup the memory data With the data backup a copy of the limited bu
111. tential bonding lead and protective conductor routed together See also For further information about radio interference suppression measures and the connecting shielded leads Configuration Manual EMC Guidelines Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BAO 153 ESD guidelines A 2 ESD measures A 2 ESD measures CAUTION The modules contain electrostatically sensitive devices Discharge yourself of electrostatic energy before touching the electronic modules The easiest way to do this is to touch a conductive grounded object immediately beforehand for example bare metal parts of control cabinet or the protective ground contact of a socket outlet NOTICE Handling ESDS modules e When handling electrostatically sensitive devices make sure that operator workplace and packing material are properly grounded e Generally electronic modules may not be touched unless work has to be carried out on them When handling PC boards make absolutely sure that you do not touch component pins or printed conductors e Components may only be touched under the following conditions You are permanently grounded by means of an ESD armband you are wearing ESD boots or ESD boots with grounding strips in conjunction with ESD flooring e Boards modules must only be placed on conductive surfaces table with ESDS surface conductive ESDS foam ESDS packaging ESDS transport container Except
112. this name You can enter a comment in the Comments text field Select the following options Version data TXT Output of the version data in the text format Configuration data XML All information about the machine identity 5 Press the OK softkey to start saving the data ix Service Manual 03 2010 6FC5397 5DP20 0BA0 65 Service cases software 3 7 Enter the tinal end user data EUNA 3 7 4 This is how you send the end user final destination data Overview The configuration file address data logbook data version data of the control can be sent to the EUNA database End User Notification Administration via an Internet connection This means that the service organization has the possibility of obtaining a profile about the history of the control without having to go to the machine Therefore service can be more effectively carried out as all of the relevant information is available Sending the end user final destination data Preconditions e The commissioning status is saved in the logbook e The machine identity has been entered updated in the machine e The machine identity was saved and is available on the PC PG The PC PG is connected with the Internet Please proceed as follows 1 Open the Internet Browser on your PC PG 2 Connection with EUNA http www siemens com sinumerik register 3 Select a language and enter an e mail address a Input of contact information T
113. ting diode LUD Local User Data Local user data MAIN Main program Main program OB1 PLC MB Megabyte MCP Machine Control Panel Machine control panel MCS Machine Coordinate System MD Machine data MDA Manual Data Automatic operating mode Manual input MLFB Machine readable product designation MPF Main Program File Main program NC part program MPI Multi Point Interface Multi Point Interface NCK Numerical Control Kernel Numerical control kernel NCU Numerical Control Unit NCK hardware unit OEM Original Equipment Manufacturer OPI Operator Panel Interface PCU Programmable Control Unit PG Programming device Pl Program Instance PLC Programmable Logic Control Programmable logic controller POU Program organization unit in the PLC user program PPU Panel Processing Unit Panel based control QEC Quadrant Error Compensation Quadrant error compensation REF POINT Reference point approach in JOG mode REPOS Repositioning in JOG mode RPA R parameter Active Memory area on the NCK for R parameter numbers RTC Real Time Clock Real time clock SBL Single Block Single block SBR Subroutine Subroutine PLC SD Setting Data SDB System Data Block SEA Setting Data Active Identifier file type for setting data SK Softkey SLM Smart Line Module SPF Subprogram file Subprogram NC SRAM Static Random Access Memory Static memory block SW Software TEA Testing Data Active Identifier for machine data TO Tool Offset Tool offset TOA Tool Offset Active Identifier file type
114. tion M4 1 8 Nm Figure 4 32 Connections DMC20 4 13 3 Overview 148 This is how you remove a DMC20 The activities that must be taken into account when replacing a DMC20 are subsequently described If a DMC20 has a hardware defect then it must be replaced by an identical module Preconditions e The module is defective and must be replaced e The control cabinet is in a no voltage condition all of the connectors and cables are labeled Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO Service cases hardware 4 13 DMC20 Removing 2 Swivel module to the front LE Mounting slide 1 Press lug downwards Figure 4 33 DMC20 removal NOTICE Electro static discharge ESD Before you touch the module discharge yourself at the cabinet or at the ground terminal Procedure 1 Before withdrawing it label the connector X524 for the electronics power supply 2 Withdraw the connected DRIVE CLiQ cables X500 X505 and write the slot designation on the cable 3 Release the protective conductor connection and write the position designation on the cable 4 Slide the lug downwards 5 Swivel the module to the front to remove it CAUTION The 50 mm clearances above and below the components must be observed Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BAO 149 Service cases hardware 4 13 DMC20 4 13 4 Installi
115. ts normally Note Note that when the system software is transferred no license key for the software of the CNC options is transferred Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO 35 Service cases software 3 3 Software backup 3 3 2 This is how you install a software backup Overview A backup previously generated is loaded into the control using the function Install software update backup All system and user data are overwritten with the software backup image Note Licenses The backup does not contain a license key a valid license key must be available on the control As an alternative the license key for an already licensed card can be obtained through the Internet See also This is how you display the actual license key Page 57 When replacing a defective system CompactFlash Card the license key must be requested again See also Licensing after replacing the system CompactFlash Card Page 51 Installing the software backup Procedure 1 Switch on the control again as the backup can only be generated when the control boots After the control has been switched on the following is displayed o Press SELECT key to enter setup menu 2 Press the lt SELECT gt key Normal startup is the default setting 3 Now press the following keys in succession Menu reset key HSK2 horizontal SK2 VSK2 vertical SK2 a v EHEHEHEH HEEE amp 2 Hardware and Softwar
116. und connection by releasing the grounding screw 10 Release the machine control panel from the control panel by releasing the clips 11 Note down the set address S2 at the DIL switch of the defective module 4 4 3 This is how you install the MCP 310C PN Installing Procedure 1 2 N 92 Set DIL switch S2 of the new module to what you previously noted down 2 Install the new machine control panel 3 Secure the clips to retain the machine control panel and tighten them 4 5 Reconnect the other cables e g the Emergency Stop cable or the button from the mini Connect the ground connection 4D handheld unit or from other command devices if available Reinsert the Ethernet cables at the X20 X21 interface port 1 port 2 Re establish the strain relief for the Ethernet cables Reconnect the power supply X10 Close the cabinet and switch on the system again Hardware and Software Service Manual 03 2010 6 C5397 5DP20 0BAO Service cases hardware 4 4 Machine control panels DIP switch S2 U 2856586888 H1 H2 H3 Figure 4 9 Switch S2 Switch S2 defines the IP address of the machine control panel 1 2 3 4 5 6 7 8 9 10 Device name on jon on off on off off off
117. unting catches click into place at the rear 3 Slide the components along the mounting rail to either the left or right up to their final position 4 Screw on the protective conductor connection 5 Screw on the encoder connecting cable to X520 and X521 X531 if required also the shield connection 6 Insert the DRIVE CLiQ cable at X500 7 Insert connector X524 for the electronics power supply CAUTION The 50 mm clearances above and below the components must be observed Hardware and Software 138 Service Manual 03 2010 6FC5397 5DP20 0BA0 Service cases hardware 4 11 5 SMC30 status displays Status displays 4 11 SMC20 SMC30 The Sensor Module Cabinet Mounted SMC30 has the following status displays which provide information about the module state LED RDY Color State OFF Description cause Electronics power supply is missing or outside permissible tolerance range Remedy Green Continuous light The component is ready and cyclic DRIVE CLIQ communication is taking place Orange Continuous light DRIVE CLiQ communication is being established Red Continuous light This component has at least one fault Note The LED is controlled irrespective of the corresponding messages being reconfigured Remove and acknowledge fault Green red Flashes at 0 5 Hz Firmware is being downloaded Flashes at 2 Hz Firmware download has
118. ut the module state LEETE sais ri we ba ee oe BG ja re of u amp 2 p a P u ots r od bd minin B a t a nibh p ui PowerOK Aip ASLE H2 AES AE DIAG1 MMe H4 eepepner HHDH DI AG2 x a H5 OVTempe Al Figure 4 16 Switch S1 and LEDs H1 to H6 H1 green H2 green H3 red H4 green H5 green H6 PowerOK PN Sync PN Fault Diag1 Diag2 OVTemp Power Off off off off off off off Power On voltage is stable on off off off off off Boot software runs and loads the system on on on on on off software System software runs on off off off off off System software runs no communication to on off off off off off the controller System software runs communication to the on on off off off off controller STOP state System software runs communication to the on Flashes at off off off off controller RUN state 0 5 Hz Overtemperature alarm on Hardware and Software 102 Service Manual 03 2010 6FC5397 5DP20 0BA0 Service cases hardware 4 5 I O modules LEDs at port 1 and port 2 There are 2 LEDs at port 1 and port 2 for diagnostics of the PLC I O interfaces based on PROFINET Figure 4 17 Port 1 and port 2 LED for communication at the RJ45 connector Name Color State Meaning Link Green ON 100 MBit link available OFF Missing or faulty link Activity Yellow ON Sending or receiving OFF No activity 4 5 5 This is how you remove the PP 72 48D 2 2A PN
119. ware 4 7 Single Motor Modules 114 5 Tighten the Torx screws of the DC link busbars observe the correct sequence amp Torx T20 amp Torx T20 6 Place the red jumper plug on the electronics busbar until it clicks into place 7 Place the 24 V terminal adapter on the electronics power supply busbar until it clicks into place 8 Close the protective cover of the DC link voltage 9 Reconnect motor connections X1 and X2 if available to the module 10 Insert the DRIVE CLiQ cables that were previously withdrawn into sockets X200 X202 11 Reinsert the enable terminals X21 and X22 if available into the module 12 Check whether all of the cables have been re connected 13 Close the cabinet and switch on the system again CAUTION Ensure that all of the connectors and screws are correctly tightened and latched or inserted J N WARNING The components must only be operated when the protective cover of the DC link is closed Damaged components must not be used Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 Service cases hardware 4 8 Double Motor Modules 4 8 Double Motor Modules 4 8 1 DMM status displays Status displays The Motor Module has the following status displays which provide information about the module state LED state Description cause Remedy Ready H200 DC Link H201 OFF OFF The electronics power supply is missing or outsi
120. ws 11 Note down the address set with DIP switch S1 on the defective module 4 5 3 This is how you install the PP 72 48D PN Installing Procedure 1 Set DIP switch S1 of the new module as you previously noted down 2 Install the new I O module 3 Connect the ground connection 4 Connect the communication cables at interface X2 port 1 and port 2 5 Re establish the strain relief for the communication cables 6 Re insert the connectors of the ribbon cables X111 X222 X333 on the module that are used to connect the digital inputs and outputs N Reconnect power supply X1 8 Close the cabinet and switch on the system again DIP switch S1 Setting of switch S1 1 2 3 4 5 6 7 8 9 10 Device name on off off on off off off off pp72x48pn9 off off off on off off off off pp72x48pn8 on on on off off off off off pp72x48pn7 off on on off off off off off pp72x48pn6 on off on off off off off off pp72x48pn5 The switch positions 9 and 10 guarantee the PROFINET functionality of the module and must always be switched on NOTICE A new address only becomes effective after voltage OFF gt ON Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 101 Service cases hardware 4 5 O modules 4 5 4 Status displays PP 72 48D 2 2A PN LEDs for status display The following LEDs on the I O module provide information abo
121. ystem description 2 1 System overview System design The following configuration shows a typical example Company network Industrial Ethernet SINUMERIK 828D Peer to peer L SINAUT MD 720 3 Z H H Non crossover modem cable PG PC ooo HEH a Q DRIVE CLIQ PLC I O interface based 2x handwheel on PROFINET oO OO Oo 12 MCP 483 PN SS PP 72 48D PN S PP 72 48D 2 2A PN Figure 2 1 Configuration example Hardware and Software Service Manual 03 2010 6FC5397 5DP20 0BA0 SINAMICS S120 C Uti ity SMC20 oe eee ee Oh SLM SMM SMM SMM i 7 E Synchronous E motor3 Synchronous Induction motor motor2 Synchronous motor1 13 System description 2 2 System versions 2 2 System versions Front panel of the different versions with interfaces 14 Protective cover f

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